Hot-runner components and systems.

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 valve-gated 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 sprues 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 System III, with an intuitive user interface, 12 to 384 zones of control, and full-color CRT graphic display of all setpoints, actual temperatures, and power outputs. All process changes are made with a light pen, which allows fast selection of all or individual zones. Diagnostic program evaluates power output, current draw, and T/C input. It reports status of the entire hot-runner system (reversed T/C, cross-wired T/C, defective T/C, open heater, etc.).

MTC-System for 4, 8 or 12 zones at 240 VAC/15 amps/zone has backlit LCD graphic display of actual temperature vs. setpoint, as well as power output. Comes standard with RS232 serial port for printing mold setups and errors.

Options for System III and MTC-System include auto-boost, auto-standby, SPI protocol communications to a remote monitor, SQC data storage, and desktop software.

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 be 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. 241.)

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.

CINCINNATI MILACRON 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. (See ad p. 53.)

CONTROL KING, INC.

Microprocessor-based 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 with the flip of a switch, which is useful for start-up, color changes, purging, and maintenance.

Systems have four to 72 zones. Control modules in 10-, 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 indication (GFI) limit. When heater ground faults are detected, appropriate action (such as forced bake) is taken automatically. When T/C breaks occur, system automatically switches to manual operation at predetermined rate of power. 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. It can change setpoints, bake time, and PID parameters.

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 serf-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/KONA HOT RUNNER SYSTEMS

Hot-runner systems feature built-in heat-pipe technology for [+ or -]5 [degrees] F temperature uniformity throughout the hot runner. Open-flow and hydraulic/pneumatic valve-gate systems for all sizes of applications from multiple-cavity, close center-to-center gating to single-cavity applications. Versions for rigid PVC a specialty. Systems available in three options: as complete systems - wired, heat tested and assembled with mold plates; as a hot-runner manifold system only; or as a Wire-Guard system that is prewired and ready for installation into the mold.

A variety of controlled-vestige (CV) hot-runner tip styles operate in the widest possible temperature range and have good color-change characteristics.

Also hot-sprue bushings, including the new single-axis valve gate, which has an open pipeline design with a large gate orifice for superior molded parts; and heaterless injection machine nozzles and temperature-control systems.

Also supplies sister company Eurotool's hot-runner temperature controls, nozzles, and manifolds for parts weighing less than 1 g up to auto bumpers. Nozzles have replaceable tip inserts. Ceramic-insulated manifolds have replaceable heaters embedded in copper for good heat transfer. Also pre-wired manifolds with tubular heaters under cover plates that can be replaced in the field.

EUROTOOL INC. See Dynisco/Kona Hot Runner Systems.

EWIKON N.A. 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 trouble, some 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. Available with various lengths, heads, and tip styles.

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 900 series analog controllers and 9000 series analog/digital controls, which maintain uniform and accurate temperatures with less than [+ or -]1 [degrees] F deviation in electrically heated areas of hot-runner tools.

The 900 series includes model 932 240VAC, 30-amp, single-zone controller used mainly on manifold zones. Standard "no-tuning" feature, PIDD analog control algorithms, and Powerpak voltage-proportioning control output. Model 943 240-VAC, 3amp (or optional low-voltage d-c), fourzone control used in runner-drop zones. Contains control, protective, and diagnostic features of the 932.

Series 9000 controls with hybrid analog/digital technology allow production data gathering and performance monitoring and provide enhanced protection features such as "slaved" or sequenced start-up.

GUNTHER HOT RUNNER SYSTEMS

Externally heated, closed-loop 5-, 24-, and 220-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. Stack systems 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. Custom or pre-engineered manifold systems, individual hot-runner components, and retrofits to upgrade cold-runner molds to hot runners available.

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.

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. (See ad p. 283.)

INCOE CORP.

Runnerless molding systems with cast heaters for mold and machine nozzles, prewired and assembled injection half of runnerless molds, and temperature-control and valve-gate control systems for runnerless molds. (See ad p. 225.)

ITALIAN TRADE COMMISSION

Information on hot-runner systems from several Italian producers.

JPI TECHNOLOGIES INC.

Heitec hot-runner system uses 220-v heating elements that provide external heating and are thermally insulated from the mold by layers of air and by a low-conductive junction element in the manifold. This eliminates need to heat up entire manifold block and substantially reduces heat loss from nozzles to cavity plate. Melt-conducting tube in nozzle is made of an alloy with high thermal conductivity and abrasion resistance. Minimum center-to-center spacing of 0.5 in. between individually controlled nozzles. Thermal separation of heating elements allows for inside gating through small cores. Top- or edge-gate multitip nozzles with up to 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 amps and wattage measurement.

KONA HOT RUNNER SYSTEMS See Dynisco/Kona.

MELT DESIGN, INC. (MDI)

Standard and special runnerless molding components include 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.

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 hotrunner 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-haft packages include hot-runner system, manifold plates, and temperature controller, delivered fully assembled, completely wired, and electrically tested.

MSI CONTROLS See American MSI.

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.

Specializes in valve-gate nozzles. Designed to run conventionally or sequentially. Gate diam. up to 1/2 in. with no gate vestige. Controlled cavity-fill rates and weld-line placement.

Mold nozzles with interchangeable tips provide flexibility in design and gate cosmetics. Material flow channels from 1/4- to 3/4-in. diam. meet requirements of large and small parts.

Multiple-gate nozzles for smaller parts have one thermocouple-controlled heater per gate. Economical and compact runnerless system with up to eight gates per nozzle.

Adjustable flow-control nozzles provide mechanical balance of fill into each cavity, placement of weld line, and good gate cosmetics.

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 fitting and starting up the system.

Extensive range of single-feed hotrunner 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.)

Hot-runner systems include manifold, hot sprue bushings, and temperature controls. Even-Flow systems are said to be especially suited to multicavity and large multidrop molds. One-piece cast, 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. Externally heated hot drops have flow paths free of restrictions.

Model 7000 temperature controller, with up to 32 zones, has 9-in. CRT with menu-type software. Max. total load is 100 kva; max. is 30 amps/zone. Data storage for up to 10 mold setups, full-time display of all zone operating parameters, RS232/484 serial output port, and optional SPC monitoring with output to a host computer. Diagnostics alarm and display control and mold electrical problems along with corrective action.

PLASTIC PROCESS EQUIPMENT INC.

Hot-runner controls from one to over 96 zones. Microprocessor-controlled PID temperature control. Some can be integrated with computer for remote control of all parameters. Low-cost, open-loop, and non-PID closed-loop modules stocked. (See ad p. 220.)

POLYSHOT CORP.

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

Heated sprue bushings of six different tip styles in 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 an FR gate interface.

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.)

RUNNERLESS TECHNOLOGY, INC. See Thermal Valve Gating, Inc.

S AND B CONTROLS

Series 8000 eight-zone temperature controller suitable for hot-runner control. PID control, autotuning, softstart, RS485 or RS232-C computer interface, digital ammeter with alarm, and run and standby setpoints. Seven-day clock for automatic warmup. Current monitoring with digital ammeter and low-current alarm provides immediate warning of heater burnout. Also Model 1000 four-zone controller.

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 independent 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. Complete technical sup, port and applications assistance. (See ad p. 243.)