Innovating mould temperature control

At Fakuma 2024 (Friedrichshafen, Germany, 15-19 October), Frigel will present its latest process cooling solutions, specifically designed to maximise productivity by significantly reducing cycle times and energy and water consumption. In the area of reducing cooling cycle times, the Tuscan company is launching the fourth generation of its super-compact Turbogel B4 mould temperature control units, which, for an investment with an average payback time of just a few weeks, mean an increase in the productivity and profitability of the production cell. The increased efficiency of the heat transfer between the recirculating water flow and the mould cavity allows the actual cooling cycle time to be drastically reduced compared to conventional TCUs.

The new units are available in Turbogel S (for injection moulding) and Turbogel P (for the packaging industry). The former is a system designed to optimise the process, improve productivity and promote high quality moulded parts. These new units have shown productivity increases of between 20 and 40% and are available in single-zone (B4SM) and dual-zone (B4SD) configurations. Each unit includes a high-performance booster pump per zone, actuated modulating cooling valve, and 6 to 24 kW heater per zone. Turbogel P units are specifically designed for low temperature injection moulding applications such as packaging and thin wall containers, caps and closures, as well as blow moulding and extrusion. Replacing direct cooling from central chillers, these units reduce the cooling cycle time of chilled water processes, increasing mould heat transfer efficiency and boosting productivity by 10 to 20%. These units are available in single and dual zone configurations, with a high-performance booster pump per zone (with or without inverter), modulating cooling valves and cooling capacity to meet the highest demands.

Other Frigel innovations at Fakuma 2024 include the Microgel Syncro RSY mould temperature control unit with patented Variotherm technology, integrated water chiller and dual-zone booster pumps. This on-board unit allows a drastic reduction in cycle time, up to 60%, without affecting the surface quality, as well as dimensional and mechanical properties of the moulded parts. The reduction in cycle time is achieved by using chilled water from the integrated chiller only during the actual cooling phase of the cycle, and by digital synchronisation with the moulding process, which provides a "deep cooling only when necessary" signal, thus reducing the cooling time while keeping the cavities warm during the injection phase. The Microgel Syncro range includes more than 10 models with cooling capacities from 16 to 56 kW and heating capacities from 12 to 24 kW. Replacing standard TCUs, this technology does not require changes to moulds or moulding parameters, making the system communicate with the press while remaining completely autonomous and easily implemented by operators.

At Fakuma, Frigel will also be presenting the Ecodry Adiabatic Cooler 4DK, a centralised closed-circuit adiabatic cooling system designed to replace cooling tower technology; 3PR 4.0, complete real-time control unit for the entire refrigeration system (parameters, functions, alarms etc.); Thermogel TDK, high-precision single-zone pressurised water TCU; Microgel RSM/RSD, a range with optimised mechanical design, increased reliability and a wide range of options, where powerful pumps and precise temperature control up to 90 °C ensure long-term high performance and improved product quality with minimum cycle times.