Hot-Runner Components and Systems.

PRODUCT LINES REVIEWED

A.L.B.A. ENTERPRISES, INC.

Thermoplay hot-runner systems from Italy include hot-runner nozzles, manifolds and temperature controllers.

Standard single-drop nozzles in two styles: Type 1 nozzle used where gate vestige is critical to a highly cosmetic appearance; and Type 2 nozzle for viscous materials or subgating into a runner when gate vestige is not critical. Also valvegated nozzles and multigated nozzles for edge gating and direct cavity gating of up to eight gates from one nozzle.

TA series nozzles have a steel tube inserted through the beryllium-copper core for improved wear and corrosion resistance. All nozzles available as hot spines for single-drop applications.

TG series temperature controllers offer individual microprocessor control of each zone and come standard with enough power for high-load applications.

AMERICAN MSI 

Runnerless temperature controls include complete line of hot-runner controls from 1 to over 360 zones. V-Series offers a variety of user interfaces such as Delta, Orion and Quantum. All hot-runner controls are completely integrated and offer mold rewiring, slaving, mold storage and Uni-start soft start, and complete diagnostics.

Hot-Runner components and systems include complete line of melt delivery systems, which feature both valvegate and open systems designs. Valvegate systems feature dual-sync pneumatics and prealigned cylindrical shut off. Advanced hot-runner systems include edge gate valve gate, abrasive systems and micro valve gates with pitches as small as 10 mm.

ATHENA CONTROLS, INC.

Hot-runner controls include mainframe (modular) single-zone units and free-standing cabinets capable of controlling up to 80 zones.

Models include the compact HRC series multizone hot-runner control computers featuring advanced tool wiring diagnostics that can automatically locate wiring faults, minimizing machine downtime while simplifying maintenance, and an easy-to-use graphical interface with onscreen help and graphing of historical data. Settings can he made by zone, group, or globally, and stored for later recall. Optional touch-screen control console, capable of being remotely mounted from the cabinet, provides network and communications capability.

Mainframe models include the IMP series controllers with dual display and CompuStep start-up in 15- and 30-amp configurations. PIM series controller, a portable single-zone version of the IMP series, is suitable for hot-sprue bushings or single-heater applications. The microprocessor-based AIM series with optional PC or SPI communications modules allows all user-adjustable parameters to be viewed or changed by a remote terminal or computer. Internal high/low deviation alarms sound, if process temperature rises above or below set values. Up to 99 AIM modules can be monitored and controlled. (See ad p. 229.)

CACO-PACIFIC CORP.

Hot-runner systems use proprietary components, including valve-gate, hot-tip, hot-edge-gate, and special custom styles in single-face and stack-mold configurations. Available as complete mold-base assemblies or bolt-on hot-half assemblies, fully assembled and tested.

CONTROL KING, INC.

Economical hot-runner temperature-control systems feature MTCS-1 control switch, which provides four different temperature setpoints for each zone. User can change back and forth between the four stored setpoints, which is useful for startup, color changes, purging, and maintenance.

Systems have four to 72 zones. Control modules in 10-, 15-, 20- and 30-amp versions can be mixed in the control cabinet according to mold-heater requirements. Each PID module accepts five different setpoints: process temperature, high/low alarms, manual power, and acceptable ground-fault (GFI) limits. When ground faults are detected, appropriate action (such as forced bake) is taken automatically. When TC breaks occur, system automatically switches to manual operation at a predetermined rate of power. Boost feature (100%), bake and standby heat are standard.

Optional KIM Module hand-held programming device plugs into any control cabinet and can be removed at any time. Any setpoints can be changed and locked-out", as well as bake time and PID parameters.

Control modules now come with optional amp readout and display.

D-M-E CO.

Runnerless molding systems and components:

* The Cool One (internally heated runnerless components and systems). Meltflow channels around heated distributor tubes provide self-insulating system, reportedly using up to 75% less energy than conventional hot runners. Single- and multilevel designs. Several probe styles for different materials or cavitation.

* The Hot One (externally heated hot-manifold systems). Nozzles, heaters, riser pads, spacer rings, etc. Three nozzle sizes and different tip styles provide a multitude of combinations to meet a wide range of material flows and part cosmetics. GateMate nozzles also provide a self-insulating layer of material in gate area. Osco multigate nozzles provide from two to eight injection points in one compact design.

* Osco hydraulically actuated single and multiple valve-gate systems have positive, independent gate shut-off. Full-body, bodiless, or pin-gate styles. External adjustment simplifies mold construction.

* Smart Series temperature controls for runnerless molds include a variety of frame and module sizes and styles for a broad range of applications. Frames accommodate one to 48 zones in 15- and 30-amp capacities. Low-voltage systems also available for molds requiring 240-v control for manifold heaters and 24-v control for nozzle drops. Control modules are microprocessor-based with multifunctional digital displays. SSM and DSS modules feature digital display of setpoint and process temperature, auto/manual mode selection, and heater-dryout function automatically actuated during start-up. CSS modules provide same features along with built-in ammeter, and in conjunction with CIM module, the ability to be remotely controlled and monitored from a PC.

Mainframes are self-contained, requiring no external relays or contactors, and offered with or without communications capability.

DMS DIEMOULD SERVICE CO. LTD.

Heatlock sprue bushings, torpedoes, and manifolds from Nils Helldin AB. All components are ceramic insulated with a variety of tips and styles, including mini models for center spacing down to 30 mm. CAD library of components is compatible with AutoCAD.

DYNISCO HOTRUNNERS

Comprehensive line of hot-runner systems, hot sprue bushings, injection machine nozzles, temperature-control systems and process simulation services.

Product styles offered with HeatPipe and MultiZone technology for wide range of applications.

Hot-runner systems available as Hot Halfs completely wired, heat-tested and assembled with mold plates; and as Wire-Guards completely wired and ready to install or as manifolds only.

Systems are used for products ranging in size from tiny medical devices to large automobile bumpers and instrument panels.

EWIKON HOTRUNNER SYSTEMS OF AMERICA INC.

Complete range of runnerless molding technology featuring both internally and externally heated systems, incorporating torpedo, multitip and valve gate nozzle technology. Internally heated systems employ patented resistive steel heating rods impervious to burnout and are designed to handle a full range of materials including highly glass- and mineral-filled, and high-temperature resins. Nozzle tip temperature control eliminates troublesome mold start-ups. Product range accommodates applications ranging from very small shot weight to shot weights in excess of 8 kg.

Full range of hot-runner control products for low 5v and conventional 230v systems. Controllers feature LCD backlit operator display unit, which shows temperature, output, alarm conditions, control mode and more on a single display. Optional computer interface provides remote downloading of recipes.

FAST HEAT INC.

Manufactures hot-runner systems and temperature controllers.

Integrally heated, flow-through design bushings: Elite series SV and LV bushings can process commodity and engineering-grade resins. Heat profile of Elite series bushing provides maximum heat transfer for superior flow. Swaged heating element is contamination resistant because of integral-heat construction of bushings. Available in various lengths and a selection of head and tip styles. Sprue bushing is also available with various heads, lengths, and diameters.

Close-pitch mini-manifold systems: Precision series bushings with internal flow and external heat are suitable for processing temperature-sensitive resins. Available for direct-feed and manifold applications, their small size allows greater flexibility in design and application. With a removable heater shield Precision bushings allow the advantage of an in-press replaceable heating element and thermocouple.

Micropoint hot-runner nozzle has a special alloy tip construction, which allows for the Micropoint to process engineering and glass-filled resins without deteriorating the tip. The nozzle design allows for easy service, low residence time of the resin, accurate volume shot size, and consistent heat profile.

Symphony 2000 series hot-runner control system is a PC-based control system capable of supervising up to 96 zones. Features include touch-screen access, simple displays, and plain-language instructions; and a decision support system, 24-hr continuous history, "field" interchangeable 15- and 30-amp modules, and optional Digi-Mold ID-an electronic storage device placed inside the mold's junction box, which allows for saving current set-up parameters with each particular mold.

GAMMAFLUX, INC.

Temperature-control systems for hot runners consist of GLC2K compact digital controller, 9500 series screen-based system, 9000 series analog/digital controller and the 900 series analog hot-runner controller. All controllers and systems accurately control temperatures with less than [+ or -][degrees]F deviation in electrically heated areas of hot-runner tools, as well as wet heater bake out, slaved start-up and sequenced start-up. All controllers utilize company's PIDD control algorithm.

Compact GLC2K controller can control up to 36 zones, each at 15 amps, and supports digital communication via RS232 or 485 interfaces.

The 9500 series is a screen-based system with PIDD control algorithm for instant control response and process accuracy. System can control up to 256 zones and incorporates comprehensive process control software in its architecture.

Series 9000 controller combines analog control with digital processing technology and is modularly designed for easy system/process diagnostics. Modules of 3, 15, and 30 amps support digital communication with plant monitoring systems via the installation of a Mini-Panel, which supports software diagnostics, menu retention, and security programs.

The 900 series is a standard controller for those who do not require digital communications and uses the PIDD control algorithm. It provides complete process diagnostics and alarm displays, as well as adaptive wet heater bakeout, and is available in 3- and 30-amp modules.

Software products available fr GLC2K, 9500 and 9000 series include GammaVision PC-based control platform; Mold Monitor, which can be used to predict heater failure; Mold Doctor for analyzing problems with hot-runner molds; and the Field Calibrator, which facilitates in-field temperature calibration.

GUNTHER HOT RUNNER SYSTEMS

Externally heated, closed-loop 5-, 24-, and 230-v hot-runner systems carry melt with minimal pressure drop through tubes from machine nozzle to gate. Internal hot elements are thermally separated from external construction elements. No heat expansion occurs between mold and hot runner.

Systems permit gating inside articles such as cosmetic caps through the unscrewing mechanism. Special nozzles in vertical or horizontal multitip arrangements with up to eight tips. Pitch diam. from 3 to 42 mm. Article weights of under one gram achievable. Can also side gate parts directly and without leaving a cold slug. Nozzles 18LER and 22LER allow for gating with one, two or four tips in a single nozzle.

Three-color and three-material tools can be designed. The additional mechanical movements of a three-color mold are not affected because of the minimal influence on thermal resources.

HASCO-INTERNORM CORP. WEST

Heated sprue bushings, nozzles, manifold blocks, and pre-assembled hotrunner systems. Internally and externally heated bushings; pneumatically operated, positive-shutoff needle valves; and temperature controls.

HUSKY INJECTION MOLDING SYSTEMS LTD.

Hot-runner systems from single-cavity units to 96-cavity, single-face and 2 x 64 cavity stack systems for part weights from 0.1 gm to 15 kg. Complete hot halves can be supplied assembled with prehardened stainless-steel plates and interface mounting holes for the cavity plate. Hot half can be attached to the cavity plate and the system started up. Systems fully wired to multipin connectors and electrically tested. Pronto hot-runner systems with delivery in four weeks and mold bases for quick delivery.

Hot-runner temperature controllers from single-zone to 128-zone units require no tuning and are highly responsive to shear heat and other process disturbances, thereby minimizing temperature cycling. Potential cycle-time reductions can be achieved by accurately maintaining setpoint temperature without risk of gate freeze-off.

Hot-runner sequential valve gate controllers for molding parts requiring individual gate control during the filling process.

IMS CO.

Closed-loop temperature-control modules rated at 15 amps and 120 or 240 v with time-proportioned power, automatic softstart, and digital display. Standard housings have 1 to 12 zones. All modules, housings, and connectors interchangeable with standard hot-runner controllers.

Open-loop power-control modules fit standard hot-runner system housings and connectors. Stand-alone closed-loop temperature controllers rated at 15 amps and 240 v in 1, 2, and 4 zones. Stand-alone open-loop voltage controllers rated at 5 or 15 amps and 120 or 240 v use company's Microstat control.

INCOE CORP.

Designs and builds hot-runner and molding systems. Manifolds; injection halves, valve-gate systems, coinjection manifolds, screen pac filters, mold nozzles, temperature and valve-gate controls, gas assist controls, electric and hydraulic mold clamps and quick-mold-change systems.

ITALIAN TRADE COMMISSION

Information on hot-runner systems from several Italian producers.

JPI TECHNOLOGIES INC.

Supplies standard and custom hot-runner components and hot halves, specializing in micro nozzles. Heitec hot-runner system uses 220-240 v heating elements that provide external heating and are thermally insulated from the mold by layers of air. Melt conveying tube in nozzle is made of an alloy with high thermal conductivity and abrasion resistance. Minimum center-to-center spacing of 0.276 in. between individually controlled nozzles. Thermal separation of heating elements allows for inside gating through small cores. Valve gate, top or edge-gate multitip nozzles with a maximum of eight tips placed on a diam. up to 3 in.

Automatic self-tuning MCS series "intelligent" temperature controllers with ITC15, RITC15, and AITC15 microprocessor-based control modules. AccuComp Cycle power control feature uses fuzzy logic to make intelligent decisions for reliability, precision, and minimization of electrical stress on heaters. Other features include audible alarm, ground fault, heater saver, security lockout, standby, and amp and wattage measurement. Multichannel temperature controllers from 5 to 240 zones pentium-based industrial PC with touch-screen or joystick operation.

MELT DESIGN, INC. (MDI)

Standard and special runnerless molding systems and components include hot manifolds, complete bolt-on systems prewired and tested, integrally heated probes, hot-sprue bushings/nozzles, two-stage externally heated nozzle filters, thermocouples, and hot-runner temperature controls.

Off-the-shelf modular hot-runner system. Modular manifolds integrally heated with replaceable thermocouples and made of tool steel. Hardened and nitrided to minimize surface wear or scoring during assembly/disassembly.

MILACRON, INC. PLASTICS TECHNOLOGIES GROUP

Runnerless temperature controller eliminates rewiring connections to the mold because heater and thermocouple locations can be changed through software using CRT menu. Available in 12 to 96 zones, system includes color monitor, type J or K thermocouple input, soft-start, and security codes. Screen graphically displays actual vs. set temperatures with high/low alarm bands. Forty-four mold setups can be stored on hard disk. Additional external storage on floppy disk. Printer port provided. Unit is caster-mounted for mobility.

MOLD-MASTERS LTD.

Standard or custom-engineered hot-runner systems from single-cavity prototypes to high-production multicavity tools in 208-240 v or 24 v to process thermoplastics in any shot size. Stack-mold hot-runner systems feature valve-to-valve feeder mechanisms for no material leaks at the first parting line.

Patented metallurgical fusion of heater element provides fast, isothermal temperature distribution and long-term heater reliability. Each system is naturally balanced with open-pipeline, unrestricted runners for repeatable cavity-to-cavity consistency, even with difficult-to-process engineering grades. All gating techniques, including hot-tip, multitip, valvegate (hydraulic and pneumatic), sprue, and edge gates.

Also minimum-pressure-loss filter nozzles, directly heated machine nozzles, and water-cooled gate inserts for use with company's nozzles to maximize gate-area cooling and shorten cycles.

Single- or multizone microprocessor-based hot-runner temperature controllers sold individually or with systems. Complete hot-half packages include hot-runner system, manifold plates, and temperature controller, delivered fully assembled, completely wired, and electrically tested.

NILS HELLDIN

See DMS.

ORYCON CONTROL TECHNOLOGY

Pre-engineered, standardized hot-runner systems and components include temperature controllers, torpedoes, sprue bushings, probes, thermocouples, modular and integral manifold system, and patented hot sprue bushings and gating bushings that use standard cartridge heaters but equalize the temperature profile to make it suitable for processing engineering resins. Manifold systems are individually engineered and are supplied as components or in fully assembled hot halves.

Temperature controllers use patented cooling method, which allows unit to operate without a fan. Dust, contaminating particles, and oil mist are prevented from entering the chassis. Microprocessor temperature controllers include single-zone units in 10, 15, and 30 amps and open- and closed-loop mode. Standard audible alarm and softstart with optional ground-fault protection. Microprocessor-based multizone mainframe controllers are standardized in 8,9 or 12 positions and may be stacked and rack mounted to achieve any number of zones. Computer interface allows local or remote setting. Control modules are self-calibrating and self-tuning with adjustable power output.

Ruggedized computer-based multizone control system for up to 120 control zones at 10 or 30 amps self adjusts for optimum running parameters and is capable of automatically correcting operator and wiring errors. System also has total manual control function.

OSCO INC.

Full spectrum of runnerless molding systems: hot tips to valve gates, multiple gate nozzles to hot sprue bushings, pre-wired manifolds to complete hot-half systems. Temperature and hydraulic control units are also available.

PLASTHING HOT RUNNER SYSTEMS, INC.

Multifeed hot-runner systems supplied on the basis of guaranteed performance including cartridge life and nonleakage of the manifold. Gate vestige height and color-change capabilities also covered by extended guarantees. Manifold system up to 128 drops designed and manufactured using in-house developed CAD and flow analysis programs, and includes installation and start-up.

Extensive range of single-feed hot-runner nozzles and multifeed bushings includes internally heated bushings based on thermocouple-controlled 24-v cartridge heaters; externally heated open flow bushings suitable for rigid PVC and similarly shear sensitive materials; multitip bushings with up to eight independently controlled tips within one bushing body; patented valve-gate bushings; and hybrid nozzles, which have been supplied up to 1300 mm, combining the gate-vestige control of the 24-v thermocouple cartridge bushing front section with low-pressure drop of the extended length rear section open-flow bushing.

PLASTIC ENGINEERING & TECHNICAL SERVICES, INC. (P.E.T.S.)

The cast, one-piece design of the Even-Flow hot-runner systems offer strength and efficient operation. Systems are said to be especially suited to multicavity and large multidrop molds. The round manifolds are said to be leak-proof without use of O-rings. They also reportedly offer 20-40% lower power consumption, smooth flow passages with reduced shear, and ability to be controlled with a single setpoint. The drops on these systems are heated and boast flow paths free of restrictions, resulting in faster start up, cooler operation and energy savings.

Model 727 hot-runner temperature controller with up to 36 zones has automatic internal switching upon detecting a thermocouple reverse condition and an automatic switch to manual mode when an open thermocouple is detected. Unit automatically shuts off when a shorted or miswired thermocouple is found. Also offered is SPI communication capability, warmup cycle, full PID control, automatic/manual control modes, and a high/low temperature alarm indicator that is activated if the temperature is [+ or -] 40F from setpoint.

PLASTIC PROCESS EQUIPMENT INC.

Hot-runner temperature controls from one to 96 zones. Units available in 15A or 30A and feature microprocessor control, soft-start and communications. Discrete temperature controls also available in sizes from 1/32 to 1/4 DIN. Features include PID autotune, fuzzy logic control and NEMA 4 x front panels.

POLYSHOT CORP.

Runnerless molding systems consist of hot-runner manifolds, heated sprue bushings, multitip nozzles and temperature-control systems.

Heated spine bushings of six different tip styles in 1 1/2, 1-or 3/4-in. diam. Tip styles include pinpoint, full-flow, reverse-taper, and large-shot types. Heated sprue bushings easily retrofitted to existing molds with a gate interface. A new heated sprue bushing features a single heater design.

Hot-runner systems are custom designed. Manifold systems externally heated for precise temperature control. Flow channels, drop lengths, and plate thicknesses sized for each application.

For maximum amount of cavities in as small an area as possible, multitip system allows two to eight drops on each module. Modules can operate in a stand-alone mode or be interfaced to company's hot-manifold system. Multitip system is suitable for high-volume, small-part applications.

Full line of manifold systems with seven different tip styles including valve gating systems. Available as complete hot halves or stand-alone systems.

Complete temperature-control systems to operate runnerless molding systems. Single-and multizone systems feature ground-fault softstart systems, PID output, solid-state digital readouts, and readouts in setpoint or direct thermocouple mode.

RAMA CORP.

Hot-runner system with runnerless design has capabilities for rapid color change and leak-proof operation. Heat-treated components reduce wear. Air-gap insulation and reduced-mass design can save energy. Cartridge, band and cast-aluminum band heaters for uniform, uninterrupted external melt heating. (See Heaters/Heating Elements.)

SEIKI SPEAR SYSTEM AMERICA, INC.

Custom or standard hot-runner systems from single cavity to high cavitation. Full integrated system with probes, hot half, and temperature controller. Hot-half systems fully wired, pretested, and ready to bolt on and run.

SH-1 probes feature single 220-240 v internal ceramic heater utilizing printed circuit patterns. Thermocouple placement at the very tip for accurate control of temperature in the gate. Designed for rigorous demands of commodity molding (PP, PE, PS, ABS).

D-Probe series internally heated, low-voltage dual-heater probes for highly technical, critical dimension, gate vestige sensitive applications. Probes contain central body heater plus separate tip heater that cycles on/off for maximum temperature control in the gate.

Multitipped probes utilize similar dual heater technology for closely spaced parts. M-Probe comes with 2, 3, or 4 tips per block in variable circle pitch and is suited for hubs or gears. I-Blocks available with 8 or 12 tips per block for commodity resins.

Thermo-Mechanical valve gate is a hybrid design using conventional pneumatic mechanical pin plus separate patented ring heater at the gate. Additional heat at the gate keeps material plasticized, eliminating the danger of gate breakage by closing the pin on a solidified gate.

SP2100 temperature controller features "soft pulse" technology for precise continuous flow of power without the on-again/off-again bursts of phase angle firing, thereby reducing stress on heating elements and providing more precise temperature control. Two operator interfaces available--full color graphics, 486-based operator interface; or a small LCD operator interface.

THERMAL VALVE GATING, INC.

Thermal Valve Gate hot-runner probes, manifolds, and controls. Probes have on/off heater control at the tip to melt the gate open and allow it to freeze shut for exceptional gate vestige control. "Cluster blocks" have 8-16 tips for small parts and 1/2 gate pitch. Split-plate manifolds make for easy cleaning. Controllers have local and remote control for adjustments in less than 10 seconds. Also heavy-duty mold connectors and cartridge heaters developed specifically for hot manifolds.

TRADESCO MOLDS LTD.

Hot-runner systems in standard and custom designs include balanced manifold assemblies and a variety of nozzle tip styles. Gating methods include diverted hot tips, sprue gates, valve gates, and edge gates. Systems come assembled, wired, and ready to install. Specializes in converting existing cold-runner molds to hot runners.

YUDO INC.

Custom-engineered runnerless molding systems and components including fully assembled, wired, and thermally tested Modu-System hot-half plate assemblies; thermodynamically balanced manifolds and gate valves; standard, custom, and single-valve nozzles; and universally compatible modular hot-runner zone mold-temperature controllers. Manifold systems available in three different types of steel and three standard thicknesses engineered to customer specifications. Supplied in standard gun-drilled form with an "edgeless" design to maximize injection velocity, or "self-cleaning" for use with difficult plastic formulations such as PVC and PBT. Technical support and applications assistance. (See ad p. 231.)