Hot-runner components and systems.

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

Supplies Thermoplay hot-runner systems manufactured by Enrietti in Italy, including 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 in both 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 for each zone and come standard with enough power for high-load applications.

AMERICAN MSI CORP.

Runnerless mold temperature controls include ATC-System II, with an intuitive user interface, 12 to 192 zones of control, and full-color CRT graphic display of all setpoints, actual temperatures, and power outputs. All process changes are made using a light pen, which allows fast, accurate selection of all or individual zones. Diagnostics 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 is designed for 4, 8 or 12 zones of control at 240 VAC/15 amps per zone. Has back-lit LCD graphic display of actual temperature vs. setpoint, as well as power output. Comes standard with RS232 serial printer port for printing mold set-ups and errors.

Both ATC-System and MTC-System offer a variety of options, including auto-boost, auto-standby, SPI protocol communications to a remote monitor, SQC data storage, and desktop software.

BARBER-COLMAN CO. INDUSTRIAL INSTRUMENTS DIV.

FITT-8000 is a multizone temperature-control system for hot-runner gates. Maintains temperature of any number of control zones to within 1 [degree]. Temperature of each zone is measured 80 times/sec and output is updated 20 times/sec.

Line-voltage compensated output changes from AutoTune PID to manual percent control at push of a button. Integral Line Cycling (ILC) operates output every 50 millisec, virtually eliminating destructive temperature gradients in heater's resistance wire. Zero crossfiring delivers control comparable to phase-angle firing, while eliminating RF noise. Softstart eliminates heater damage from insulation moisture, while Auto-Comp provides a means of continuing production if thermocouple is damaged. Coordinated Overcurrent Protection (COP) offers triple-redundant protection against short circuits without replacement of fuses. "Plain English" dis, play of volts and amps provides instant heater status at no extra cost. Alarm output and 32 diagnostic events standard. Controller housing sealed against production-area environments, and NEMA 4 enclosures designed per specification. Cable connectors for most existing mold connectors are standard.

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 prior to shipment.

CINCINNATI MILACRON U.S. PLASTICS MACHINERY DIV.

Runnerless mold temperature controller eliminates the need to rewire connections to the mold, because heater and thermocouple locations can be changed through software using CRT menu. Available in modules of four zones from 12 to 96, system includes color monitor and 16-key operator interface, type J or K thermocouple input, PIDD adjustment, 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 drive. Additional external storage capacity available through floppy-disk drive. Printer port provided. Compact unit is caster-mounted for mobility.

CONTROL KING, INC.

Microprocessor-based temperature-control systems for hot-runner molding feature Master Temperature Control Switch (MTCS-1), which provides choice of four different temperature set-points for each zone. User can change back and forth between any of the four separate setpoints with the flip of a switch and still maintain the four originally entered setpoints for each zone, an advantageous option for start-up, color changes, purging, and maintenance.

Systems begin at four zones, increasing in increments of two up 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 alarm, low alarm, manual power, and acceptable ground-fault indication (GFI) limit. Six process displays, such as power level and optional GFI indicators, accessible at touch of a button. Power-level display gives percentage of power consumed per zone. With GFI display option, heater ground faults are detected and displayed; and appropriate action (such as forced bake) is automatically taken. Modules also display fault and alarm conditions, heater/thermocouple diagnostics, and contain audio/visual alarm system. When T/C breaks occur, system automatically switches to manual operation at predetermined rate of power, maintaining desired setpoint temperature. Bake and standby heat standard.

Optional KIM Module, a hand-held programming device, plugs into any control cabinet and can be removed at any time. It can "lockout" or "unlock" any of the five different setpoints, change bake time, change any PID parameters, and enter any setpoint for an individual zone or all zones.

D-M-E CO.

Runnerless molding systems and components:

* The Cool One (internally heated runnerless components and systems). Melt-flow channels around heated distributor tubes provide self-insulating system, reportedly using up to 75% less energy than conventional hot runners. Systems configured in single- and multi-level designs. Several styles of probe drops suit different materials or cavitation.

The Hot One (externally heated hot-manifold systems). Nozzles, heaters, riser pads, spacer rings, etc. Three nozzle sizes and four tip styles provide 27 combinations to meet a wide range of material flow and part cosmetics. Gate-Mate nozzles can also provide advantages of a self-insulating layer of material in gate area. Osco multigate nozzles provide four or six injection points in one compact design.

* Osco single- and multiple valve-gate systems. Hydraulically actuated systems provide positive, independent gate shut-off. Full-body, bodyless, or pin-gate styles. Single valve-gate system features a shaft-driven 1:1 ratio for long life and external adjustment to simplify mold construction.

* Osco adjustable-flow systems. Nozzles permit external adjustment of flow rate for balancing family molds.

* Smart Series temperature controls feature digital readouts, auto and manual modes, heater warm-up circuitry, and self-diagnostics for thermocouple faults. Single- and dual-readout models, as well as computer interface for remote control via PC or machine interface. Standard accessories and special systems on a quotation basis.

EWIKON N.A. INC.

Low-voltage (5-VAC) energy-efficient hot-runner systems with complete line of components. Support and service from mold design to final injection process.

A 5-VAC or 240-VAC hot-runner temperature controller with four-field monitor "window" technique is multi-zone, microprocessor-based, PID self-tuning, and reacts to [+ or -]1 [degree] F change from setpoint. Digital LED display, soft-touch data keypad, ground-fault detection, softstart, thermocouple break protection, percentage output of all zones or a single zone, error analysis, and fault display. Units switchable from amps to [degrees] F. Interface linking to IBM PCs available for SPC information.

FAST HEAT INC.

Runnerless systems emphasize balanced design in every manifold. System manufactured using CNC technologies, including flow analysis when required. Everything on hot half, from mold plates to integrally heated torpedo bushings, is manufactured by the company.

* Temperature controllers: Conductor Series microprocessor control modules in cabinets with one to 12 zones. Multizoned free-standing cabinets available. Can sense T/C failure and switch automatically to continue running at steady-state. AutoSoft warm-up, percent-of-power display, dual-function set-point, [degrees] F or [degrees] C display, three alarms, 14 self-diagnostic features, and U.S. or European power ratings.

* Gating and runner torpedoes: Sensitip molding torpedoes are swaged to provide more uniform heat profile than cartridge-heated types. Diam. of 0.312 to 0.750 in. and wide selection of lengths. Torpedo has replaceable type J thermocouple located internally and up front for precise gate and runner temperature control. Gating torpedoes in diam. from 0.394 to 0.750 in.

* Torpedo bushings: Sensitwin bushings are integrally heated and designed to perform beyond the capabilities of ordinary cartridge-heated probes and coil-heated bushings. Three basic configurations for single-cavity, manifold or stack-mold applications.

* Sprue bushings and machine nozzles: Integrally heated and patented design includes replaceable type J thermocouple. Sprue bushings come with 0.50- or 0.75-in. radius on the head, flat, or manifold style. Tips of bushings can include extra machining stock.

GAMMAFLUX, INC.

Electronic temperature-control systems for hot-runner molding consist of 900 series analog controllers and 9000 series analog/digital controls. Maintain uniform and accurate temperatures typically with less than [+ or -]1 [degree] F deviation in electrically heated areas of hot-runner tools.

The 900 series includes model 932, a 240-VAC, 30-amp, single-zone controller used primarily on manifold zones. Standard "no-tuning" feature, PIDD analog control algorithms, and Powerpak volt-age-proportioning control output. Model 943 is a 240-VAC, 3-amp (or optional low-voltage d-c), four-zone control for use in "drop" zones. Contains all control, protective and diagnostic features of model 932.

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

GUNTHER HOT RUNNER SYSTEMS

Externally heated, closed-loop 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 diameters from 3 to 42 mm. Article weights of under one gram achievable.

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

HASCO-INTERNORM CORP. WEST

Wide range of heated sprue bushings, nozzles, manifold blocks, and pre-assembled hot-runner systems. Internally and externally heated bushings; pneumatically operated, positive-shutoff needle valves; and variety of 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. Can be supplied fully assembled with pre-hardened stainless-steel plates and interface bolt holes for cavity plate. Fully wired to multipin connectors and electrically tested. On delivery, hot half is ready to be attached to cavity plate and run. Individual components also available. Evaluation and engineering service to upgrade cold-runner molds to hot-runner systems.

IMS CO.

Cartridge heaters with built-in, type J thermocouples from 1/4 x 1 1/2 in. to 5/8 x 10 in. Wattages from 200 to 5000 w.

Closed-loop temperature-control modules rated at 15 amps and 120 or 240 v with time-proportioned power, automatic softstart, and analog or digital display. Standard housings have 1 to 12 zones. Also single-zone housings with 30-amp output working off a standard 15-amp module. All modules, housings and connectors interchangeable with standard hot-runner controllers.

Stand-alone closed-loop temperature controllers rated at 15 amps and 240 v in 1-, 2- and 4-zone models.

Open-loop power-control modules fit standard hot-runner system housings and connectors.

* Stand-alone, open-loop voltage controllers rated at 5 or 15 amps and 120 or 240 v use company's microcircuit control.

INCOE CORP.

Runnerless molding systems, cast heaters for mold and machine nozzles, prewired and assembled injection haft of runnerless molds, and temperature-control systems.

ITALIAN TRADE COMMISSION

Information on Hot-runner systems from several Italian producers.

JPI TECHNOLOGIES INC.

Offers Heitec hot-runner system. The 220-v cast-in heating elements, which provide external heating, are thermally insulated from mold by layers of air and by low-conductive junction element in 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 0.71 in. between individually controlled nozzles. Thermal separation of heating elements allows inside gating through small cores. Top- or edge-gate, multitip nozzles with up to eight tips placed on a diam. up to 3 in.

KONA CORP.

Hot-runner systems feature built-in, patented heat-pipe technology for [+ or -]5 [degrees] F temperature uniformity throughout the hot runner. Systems for all sizes of applications, from multiple-cavity, close center-to-center gating (caps, closures, medical parts) to single-cavity applications (automotive bumpers, instrument panels). Versions for rigid PVC a specialty. Systems pre-wired and pre-assembled with integral mold plates for easy installation. Also hot-sprue bushings, injection machine nozzles and temperature-control systems.

MELT DESIGN, INC. (MDI)

Standard and special components for runnerless injection molding systems include integrally heated probes, hot-sprue bushings/nozzles, two-stage externally heated nozzle filters, thermocouples and hot-runner temperature controls.

Off-the-shelf, pre-engineered, pre-dimensioned, modular hot-runner system. Modular manifolds are integrally heated with replaceable thermocouples and are made from high-quality tool steel. They are hardened and nitrided to minimize surface wear or scoring during assembly/disassembly. Design consultation and engineering assistance available on new tooling and retrofits.

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. Stackmold hot-runner systems feature valve-to-valve feeder mechanisms for no material leakage at the first parting line.

Patented metallurgical fusion of heater element provide 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, valve gate (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.

Application engineering assistance and technical seminars on new technology and processing developments.

ORYCON CONTROL TECHNOLOGY

Specializes in pre-engineered, standardized hot-runner systems and components, including temperature controllers, torpedoes, sprue bushings, probes, thermocouples, modular manifold system, and a hot sprue bushing that uses standard cartridge heaters, yet is capable of equalizing the temperature profile, making it suitable for processing engineering resins.

Temperature controllers use patented cooling method, which allows unit to operate without a fan. This is said to prevent dust, contaminating particles, and oil mist from entering the chassis. Microprocessor-enhanced temperature controllers include single-zone units in 10-, 15- and 30-amp loads and open- and closed-loop mode. Standard audible alarm and soft start-up with optional ground-fault protection. Multizone mainframe controllers standardized in 9 or 12 positions and may be stacked to achieve any number of zones. Control modules available in PID with digital LCD display and adjustable power output.

OSCO INC.

Specializes in valve-gate nozzles. Designed to run conventionally or sequentially, valve-gate system allows gate diameters 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 1/.2-in. diam. meet requirements of large and small parts.

Multiple-gate nozzles for smaller parts have one thermocouple-controlled heater per gate. Capacity to eight gates per nozzle provides economical and compact runnerless system.

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.

Extensive range of Italian-designed single-feed hot-runner nozzles and multifeed bushings. Designs and builds complete manifold systems with up to 96 drops using CAD and flow analysis. Nozzles and bushings employ internal 24-v cartridge heater that extends the whole length of the unit. Low heater voltage protects unit from damage by moisture, without need for soft-start. Simple voltage control without need for thermocouples. The 24-v cartridge provides sufficient control to prevent drool without mechanical shutoff. Titanium-coated bushings offered for use with abrasive glass-filled materials.

Manifolds incorporate special 240-v cartridges with unusually low watt-density. Systems achieve a "natural seal" by means of thermal expansion of close-fitting components, so no special seals, sealing rings or springs are required to prevent leakage.

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. Valve gates and low-vestige tips available.

P.E.T.S. Model 7000 temperature controller, with up to 32 zones in multiples of eight, has 9-in. CRT with menu-type software. Max. total load is 100 kva; max. per zone is 30 amps (40 amps optional). Housed in rugged, dust- and oil-tight NEMA-style enclosure, controller offers 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 instantly alarm and display control and mold electrical problems, as well as corrective action to be taken.

PLASTIC PROCESS EQUIPMENT INC.

Hot-runner controls include all accessories and systems from single zone to over 96 zones. Modules are microprocessor controlled and offer 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.

POLYSHOT CORP.

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

Heated sprue bushings consist of six different tip styles in 1- or 3/4-in. diam. Tip styles include pinpoint, full-flow, reverse-taper and large-shot configurations. Heated sprue bushings can easily be retrofitted into existing molds with the use of an FR gate interface.

Hot-runner systems constructed to customer's requirements. 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 individual drops to be included on each module. Modules can operate in a standalone mode or be interfaced to company's Hot Manifold System. Multitip System is suitable for high-volume, small-part applications.

Also furnishes complete temperature-control systems to operate its runnerless molding systems. Single- and multiple-zone configurations feature ground-fault softstart systems, PID output, solid-state digital readouts, and ability to read out in setpoint or direct thermocouple mode.

RAMA CORP.

True Shot runnerless molding system has reportedly unique capabilities for rapid color change and leak-proof operation. Heat-treated components to reduce wear, and air-gap insulation and reduced-mass design are said to result in energy savings. Ramarod cartridge, Ramaband and Rama cast-aluminum band heaters provide uniform, uninterrupted, external melt heating.

Engineering and R&D services using CAD available for custom-designed heating assembly needs.

S AND B CONTROLS DIV. OF SCHUNTERMANN CORP.

Series 8000 eight-zone temperature controller is suitable for hot-runner control. PID control, autotuning, soft-start, 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--much faster than a low-temperature alarm. Company also offers Model 1000 four-zone controller.

SPEAR SYSTEM, INC.

Internally heated hot-runner probes employ patented Thermal Valve Gating process, where by a separate second heater at the tip of probes cycles on and off, providing absolute control at the gate. Both heaters use low voltage, virtually eliminating burnout. Also, multitip cluster blocks offer individual control of both tip temperature and tip "on" duration.

Systems eliminate stringing, drooling, or cold slugs at the gate; allow faster cycle times from increased cooling at the gate and in cavity plate; permit fine-tuned gate balancing, change of flow rate, or variance of pressure from cavity to cavity for the highest yield of parts; offer "lights-out" operation because there are no moving parts; and leave a gate vestige under 0.10 in.

SYSCON-RKC SYSCON INTERNATIONAL, INC.

Model 530 HR hot-runner temperature controller has Microcycle feature that updates controls every 8 millisec so as to minimize temperature overshoot. Soft-start protection, integral SPC capability--which communicates with a separate PC running Syscon's SPC software--and SPI communications protocol, which allows hot-runner control to be integrated with molding machine control.

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 supplied assembled, wired, and ready to install.

Specializes in retrofitting existing cold-runner molds to hot-runner molds, including testing.