In an injection plant, thermal control of the mold is usually one of the largest electrical consumers that goes unnoticed. Circulation pumps run many hours a day, often at full speed continuously, whether the process requires it or not. That's where the waste and, therefore, the opportunity is concentrated.

How much energy does a temperature control unit consume?

Consumption depends above all on the power of the pump and how it is regulated, rather than on the heating, which only acts to reach the setpoint and compensate for losses. A fixed speed pump always delivers the same flow rate and pressure, whether justified by the process or not, and that excess becomes wasted electricity and heat that must then be removed. Reducing that base consumption is what makes the investment in efficient equipment pay off.

The five levers of energy saving

The equipment is the basis, but the real savings come from combining several measures. These are the five that have the most weight.

1. Variable speed pump

Compared to a fixed speed pump, a regulated pump adjusts flow and pressure to what each process requires. As the power consumed increases sharply with speed, lowering the revs to what is strictly necessary cuts consumption disproportionately. It is, in most installations, the lever with the greatest impact.

2. Correct sizing and flow

Oversizing equipment or moving more flow than necessary does not improve the part and does increase consumption. The objective is the right flow rate to achieve turbulent regime in the mold and maintain the thermal jump between inlet and return within tolerance. Neither more nor less.

3. The choice of fluid and system

Working with water whenever the temperature allows it is more efficient than using oil, because water transfers heat better. At MARSE we manufacture temperature control units —also called thermoregulators or TCU— water with open tank, pressurised water direct and indirect heating, and oil with tank or closed circuit, precisely so that each process uses the most efficient system for its range and not an excess one. A system with a low volume of circulating fluid also requires less energy to heat and cool. If you hesitate between one and the other, you have it developed in water or thermal oil: how to choose the fluid.

4. Flow distribution by circuits

Distributing and monitoring the flow by zones of the mold allows each circuit to be fed in a balanced way and, in many cases, to serve with a single piece of equipment what previously required two. Our solutions multi-circuit distribution and of flow monitoring They are designed for that: less equipment running, same process control and lower consumption.

5. Shorten and insulate hoses

Placing the temperature control unit near the machine reduces the length of the tube, and with it the resistance that the pump overcomes and the heat losses to the environment. The insulation weighs more the higher the temperature of the fluid: above a certain point, the losses through the hoses grow sharply and isolating them is no longer a detail.

How much can you save? An illustrative example

The following calculation is an indicative example with common values ​​in the sector, not a guaranteed figure. Each installation must be measured. Let's assume a medium temperature process in which, adding the switch to a variable speed pump, the correct sizing of the flow and the reduction of equipment for distribution, the electrical consumption of the system drops from about 4 kW to less than 1 kW, that is, around 3.5 kW less.

In three-shift operation, of the order of 6,000 hours per year, and with an electricity price of approximately €0.17/kWh, the savings would be about €3,570 per year per team. In plants with many of the same pieces of equipment, these savings are multiplied. With these specific figures the return is quick, but it is worth insisting: the amortization period depends on the price you pay for energy, your real hours of operation and the starting point of your installation. There is no universal figure.

How to calculate your own return

The formula is simple and you can apply it with your real data:

• Annual savings (€) = power difference in kW (before − after) × operating hours per year × price per kWh
• Return period (years) = investment ÷ annual savings

For the calculation to be reliable, it is necessary measure the actual consumption before and after, not estimate it, because the differences between a fixed pump at full load and a regulated one are usually greater than expected. This approach fits with what we explain in reduced total cost of ownership: What counts is not the purchase price, but what the equipment costs throughout its life.

The savings do not end at the electricity bill

Reducing consumption brings benefits that do not appear on the bill but count just the same. Equipment that does not work at full load suffers less wear, which lengthens its useful life and reduces maintenance. A controlled and stable flow rate improves the repeatability of the process and, with it, the quality of the part and the waste. And less consumption means fewer associated emissions, something increasingly relevant in sustainability strategies and in customer and audit requirements. Overall, energy efficiency and process reliability go hand in hand.

Frequently asked questions

How long does it take to pay for an efficient temperature control unit?

It depends on the avoided consumption, the hours of operation and the price of energy, so there is no valid figure for everyone. In installations that move from fixed speed pumps to well-sized modern equipment, the return is usually quick, but the only correct way to know is to measure consumption before and after and apply the savings formula with your own data.

What saves the most in a temperature control system?

In most cases, the variable speed pump, because the power consumed grows a lot with speed and adjusting it to the necessary flow rate cuts consumption disproportionately. This is followed by correct sizing and equipment reduction through flow distribution.

Does a water or oil temperature control unit consume more?

In its working range, water transfers heat better and usually consumes less, so it is advisable to use water, with a tank or pressurized, whenever the process temperature allows it, and reserve the oil for temperatures that water does not reach.

Does insulating the hoses help?

Yes, especially at high temperatures, where heat losses through the hoses increase rapidly. Shortening them by placing the equipment near the machine, in addition to isolating them, reduces losses and stress on the pump.

Can I reduce the number of temperature control units in my plant?

In many cases yes. With adequate flow distribution and monitoring, what previously required several pieces of equipment can be fed and controlled in a balanced way, maintaining the stability of the process and lowering overall consumption.

Shall we calculate your savings?

At MARSE we have been manufacturing water and oil temperature control units since 1978, with more than 80,000 units installed in more than 70 countries. If you want to know how much you could save in your installation, tell us your process, the hours of operation and your current consumption and we will help you estimate the return with your figures.

Talk to a MARSE technician or scribe to marse@marse.es.

Related readings: temperature control units for injection molds · lime and scale in the mold circuit · connectivity and Industry 4.0.

At MARSE we manufacture temperature control units —also called thermoregulators or TCUs— since 1978, and most of the performance incidents that we see in the field do not come from a failure of the equipment, but from the fluid that circulates through it. It is the cheapest breakdown to prevent and the most expensive to ignore.

Why does scale ruin thermal control?

The mechanism is reverse solubility. Calcium carbonate and calcium sulfate dissolved in water become less soluble as the temperature rises, so they precipitate right where it doesn't matter: on hot heat transfer surfaces. The hotter the channel wall is, the faster the deposit grows. Surface temperature weighs much more than fluid velocity on crust formation, so increasing the flow rate helps, but is not a substitute for treating the water.

The problem is that lime conducts heat very poorly. Published measurements place the average thermal conductivity of lime around 1,37 W/(m·K), compared to about 15 W/(m·K) for steel and about 230 W/(m·K) for aluminum. That is, a layer of lime insulates approximately ten times more than the mold steel itself. That is why a deposit that is barely visible when opening a circuit can have a disproportionate effect.

The published research gives an idea of ​​the order of magnitude. A simulation work estimates that one millimeter of lime reduces around one six percent the efficiency of the cooling circuits and doubles the effect that a millimeter of oxide would have on the surface temperature of the mold and on the warping of the piece. The same work concludes that a quarter of a millimeter of deposit barely prolongs the solidification time, but a millimeter clearly penalizes it, and that two millimeters nullify the advantage of conformal cooling, leaving it at the level of a conventional drilled channel. Considering that refrigeration can account for the majority of the cycle time, that percentage is paid on each part.

There is a second, less discussed effect. As the channel section narrows, the equipment needs more pressure to move the same flow, and in the most severe cases the simulations record pressures that exceed what a standard commercial temperature control unit delivers. Long before it gets there, the pump is already working outside its optimal point, consuming more and wearing out prematurely.

Source of simulation data: Zink, Héri-Szuchács, Hajagos and Kovács, “Modeling the effect of scale deposition on heat transfer in injection molding”, Scientific Reports 15 (2025).

What water does a temperature control unit admit: reference parameters

These are the values ​​that MARSE recommends for the cooling water of its equipment. They are not a commercial suggestion: below these thresholds the equipment behaves as designed, and above these thresholds appear corrosion and deposits that are not covered by the warranty.

• pH: between 7.5 and 8.5
• Conductivity: inferior a 150 mS/m
• Total hardness: less than 15 German degrees
• Carbonated hardness: less than 4 German degrees, or less than 20 if stabilized
• Chlorides: inferior a 100 mg/l
• Sulfates: inferior a 150 mg/l
• Ammonium: inferior a 1 mg/l
• Hierro: inferior a 0,2 mg/l
• Manganese: inferior a 0,1 mg/l
• Suspended solids: none

There are three nuances that should not be overlooked. With stainless steel, the chloride limit depends on the working temperature: up to 50 °C it allows 100 mg/l, between 50 and 90 °C it drops to 50 mg/l, and above 90 °C it drops to 30 mg/l. With aluminum, the pH window narrows to a range of 7.0 to 8.0. And below 5 °C, an antifreeze with a corrosion inhibitor must be added, taking into account that glycol should not be used above 120 °C.

To stay within these margins, it is usual to treat the water with an anticorrosive, a non-ferrous metal protector and a hardness stabilizer. In areas with hard tap water, a softener or the use of demineralized water with an inhibitor is usually cheaper than the accumulated cycle loss. You can expand on this point on our page about fluid quality, and the magnetic filters They help retain metal particles that accelerate circuit fouling.

How do I know if I have encrustations? Warning signs

Embedding does not warn all at once: it degrades the process little by little, and that is why it ends up normalizing. These are the signals that should trigger a circuit inspection.

• The equipment takes longer to reach the setpoint or has difficulty maintaining it at full capacity.
• The thermal difference between the flow and return widens with respect to the start-up values.
• The flow rate drops, or the delivery pressure rises to move the same flow rate—a classic sign of an obstructed section.
• The cycle lengthens without anything having changed in the mold or the material.
• Uneven cooling defects appear, such as warping or sinkholes in specific areas of the piece.
• In the worst case, the pump sounds different or the equipment goes into alarm due to temperature.

The reliable way to confirm this is to compare with the reference: record flow, pressure and thermal jump when the installation is clean and measure them again periodically. A temperature control unit with flow monitoring It makes this monitoring much easier, because the drift is seen on the screen before it is noticed on the piece.

How to prevent scale and what to do if you already have it

Prevention is a short and boring protocol, which is exactly what it should be. Analyze the make-up water before starting up and do not assume that the mains water complies. Treat the circuit with the appropriate additives and check their concentration periodically, not just on the day of installation. Check the filters and avoid continuously adding new water, because each new liter brings new salts. Maintain a sufficient flow rate to ensure a turbulent regime, which delays the formation of the deposit. And it records the reference parameters of the installation to be able to detect drift.

If the deposit has already formed, chemical cleaning with a descaler compatible with the circuit materials is the usual route, followed by neutralization, rinsing and replacement of the treatment. It is advisable to do it with the correct product: an acid that is too aggressive can resolve the limescale and create a greater corrosion problem, especially in circuits with aluminum or with sensitive joints. After cleaning, check the condition of the pump, exchanger and probes, because they are usually the components that have suffered the most.

Thermal oil also has requirements

In high temperature equipment the fluid is not water, but the logic is the same: the fluid determines reliability. MARSE requires high quality synthetic oils to prevent premature degradation, with a kinematic viscosity at 40°C of 15 a 26 cSt, and minimum flash point 170°C and a working range of −20 to +320 °C. A degraded oil forms sludge and varnish that dirty the exchanger with the same effect as lime: less transfer and more consumption. If you work above 150 °C, periodic checking of the condition of the oil should be in your maintenance plan.

Frequently asked questions

What water hardness does a temperature control unit accept?

For reference, a total hardness below 15 German degrees and a carbonate hardness below 4 German degrees, or up to 20 if stabilized with an additive. Above these values, the precipitation of lime on hot surfaces accelerates and it is advisable to decalcify or treat the water.

How much does fouling affect cycle time?

It depends on the thickness. Published research indicates that a quarter of a millimeter barely prolongs solidification, while a millimeter already significantly reduces the efficiency of the circuit and two millimeters can nullify the advantage of conformal cooling. Since refrigeration takes up a good part of the cycle, even a small percentage is noticeable in annual production.

Why doesn't my temperature control unit cool like before?

The most frequent causes are incrustation in the exchanger or in the mold channels, a dirty filter, air in the circuit or a worn pump. If the pressure necessary to move the same flow rate has also increased, the tank is the most probable hypothesis and it is time to inspect the circuit.

How often should the cooling circuit be cleaned?

There is no single interval: it depends on the hardness of the water, the working temperature and the hours of operation. The effective thing is not to set a date, but to monitor the drift of flow, pressure and thermal jump with respect to the reference values ​​and act when it appears.

Can I use demineralized or osmosis water?

Yes, and it greatly reduces the risk of scale, but very pure water can be aggressive with some metals, so it should always be used with a corrosion inhibitor and respecting the pH window of the circuit material, which is narrower in the case of aluminum.

Do we check the water in your facility?

At MARSE we have been manufacturing water and oil temperature control units since 1978, and we provide after-sales support to equipment installed around the world. If you suspect that your installation is losing performance due to scale, or you want to check if your plant's water meets the requirements, tell us your process and the values ​​of your make-up water and we will help you interpret them.

Talk to a MARSE technician or scribe to marse@marse.es.

Related readings: water or thermal oil: how to choose the fluid · mold temperature table by polymer · reduced total cost of ownership.

The decision table

The summary in one line: If your process fits in water, it goes in water. Oil is not "the superior option", it is the option for when water no longer reaches it.

Where is the real border

Here the decision is made wrong more often. Many plants jump directly into the oil as soon as they go above 90 °C, when between 90 and 160 °C pressurized water is usually a better option in almost everything: it transfers much better, responds faster, does not degrade, does not smell, does not get dirty and does not burn.

Pressurized or open tank

Within each fluid there is a second decision that is overlooked, and it is the one set by the team family:

A practical note about pressurized water: the minimum working pressure increases with temperature, around half a bar for every 10 °C above 90. At 150 °C that is about 4.5 bar. It is not a problem, but it conditions the installation and it is advisable to know it before, not after.

A temperature control unit is not a chiller

They get confused every day, and the confusion is expensive because the wrong equipment is purchased.

The usual thing is to need both, and for them to work together: the chiller gives the cold, the water or oil temperature control unit decides the temperature of the mold. There is a case in which the chiller is no longer optional: if the cooling water enters at a temperature that is too close to the process temperature, the available jump is so small that cooling is no longer reliable. There you need a closed circuit with a chiller, not more power.

Frequently asked questions

Is a water or oil temperature control unit better?

The water one, as long as your working temperature allows it. It transfers heat much better, responds faster, consumes less and the fluid is free. The oil only compensates when you need to go above 160°C. Our water range reaches 180 °C and oil range up to 300 °C.

At what temperature do you need oil?

Our selection criterion is 160 °C. Below, if you have the choice, pressurized water is usually a better decision. Above, and always in injected metal or with PEEK and PPS, is oil.

Up to what temperature does a water temperature control unit go?

With open tank, 90 °C, because water boils at 100 °C at atmospheric pressure. With pressurized circuit, up to 180 °C.

Up to what temperature does an oil temperature control unit go?

Up to 300 °C in closed circuit. With open tank, up to 150 °C.

What is the difference between a temperature control unit and a chiller?

The temperature control unit maintains a set temperature and to do so it heats and cools, normally above the ambient temperature. The chiller only produces cold, below the ambient. They are complementary teams, not alternatives.

Does oil need more maintenance than water?

Different, not necessarily more. Oil degrades over time and temperature, and must be analyzed and changed. The water does not degrade, but it encrusts: without treatment, the lime ruins the heat exchange and the problem appears sooner than people expect.

Can I go from oil to water in an existing installation?

If your working temperature is below 160 °C, almost always yes, and it usually pays off in consumption and maintenance. The circuit must be cleaned thoroughly and gaskets and materials checked. It's a conversion we make frequently.

A manufacturer since 1978

We manufacture water and oil equipment, so we have no commercial preference for either: we have a preference for the one that makes your process last. Tell us the working temperature, the current fluid and what is failing you, and we will tell you what we would do. If you are also deciding on the setpoint, consult our mold temperature table by polymer, o talk to a technician.

This guide summarises the decision. If you need the full technical detail — working ranges for each fluid, behaviour above 90 °C and sizing criteria — it is set out in water or thermal oil: how to choose the fluid.

This table compiles typical mold temperature ranges by polymer family. But the correct temperature is of no use if the equipment cannot sustain it: that is why the second half of the article is the one that really matters, and it is the one that is almost never published.

Mold temperature table by polymer

Guidance ranges. The specific grade and fiber load always govern this table: consult the material supplier's file.

Rule of thumb: Fiber-reinforced grades typically ask for the high end of the range, and sometimes above. In semicrystalline mold temperature is not a finishing adjustment: it is what decides the crystallinity, and with it the rigidity, dimensional stability and long-term behavior of the piece.

Do not confuse it with the temperature of the plastic

It is worth stopping here, because it is the most expensive confusion in the sector: in an injector several temperatures coexist and only one controls the temperature control unit.

• molten mass (200–300 °C depending on polymer): the plastic coming out of the screw. The injector puts it on. The temperature control unit does not control it.
• Mold surface (the table above): the steel against which the part solidifies. This one yes.
• equipment fluid: a means to achieve the previous one, never an objective.

If your ABS melts at 240°C, you don't need a 240°C temperature control unit: you need one that keeps the mold between 40 and 80°C. The difference between understanding this and not understanding it is two radically different teams and a budget that is nothing alike.

The part that almost no one tells you: maintaining it

Choosing the number is the easy part. The real problem appears later, and it has three faces.

The temperature jump, not the temperature

A mold is not at a temperature: it is at a temperature map. What determines the quality of the part is not so much the setpoint as the ΔT between input and return and the homogeneity between circuits. A mold with the correct setting and 8 °C difference between zones produces equal warping.

Flow rate matters more than power

If the flow in the channels is not turbulent, the heat is not extracted no matter how much cooling power you have behind it. It is the most expensive and most common mistake: power is bought when the problem was flow rate.

Above 90 °C the physics changes

Water at atmospheric pressure boils at 100 °C, so in practice an open circuit stays around 90 °C. From there there are two ways: pressurize the water or switch to oil. And that decision conditions the entire installation.

What equipment each range calls for

Our range covers from 25 to 180°C in water and up to 300°C in oil. This is the criterion with which we select family:

The border between water and oil is not where people think: we select oil above 160 °C. Below, and if you can choose, pressurized water is usually a better decision. We develop it in water or oil: how to choose the temperature control unit.

Frequently asked questions

What mold temperature does ABS need?

Between 40 and 80 °C in most degrees. Below 40 °C the gloss becomes irregular and the weld lines become marked; Above 80 °C you lengthen the cycle without gaining anything. A water temperature control unit with a tank covers the entire range.

And polypropylene (PP)?

From 20 to 60 °C. It's a semi-crystalline, so the mold temperature decides the shrinkage: if you're looking for dimensional stability, go up within the range and keep the ΔT low between circuits.

My plastic melts at 240 °C, do I need a 240 °C temperature control unit?

No. Those 240 °C are the temperature of the melt and are set by the injector. The temperature control controls the surface of the mold, which in ABS works between 40 and 80 °C. A water system with a tank more than covers that range. It is the most common mistake we see and it multiplies the budget for no reason.

At what temperature do I need pressurized water?

From 90 °C. Water at atmospheric pressure boils at 100°C and an open circuit doesn't get there with any margin. Pressurizing works with water up to 180 °C, preserving the thermal advantage of water over oil.

Why does my piece come out warped if the instructions are correct?

Because the reference is not the temperature of the mold. Almost always the problem is the ΔT between input and return, or the difference between circuits, not the number on the display. Before touching the setpoint, measure the difference between zones and check that the flow is turbulent.

Why does PEEK need 170–200°C?

Because underneath it doesn't crystallize. An amorphous piece comes out that loses a good part of the mechanical and thermal performance for which the material is paid. In that range there is only one realistic option: oil.

A manufacturer since 1978

This table summarizes what we see every day in the plant: most of the problems attributed to the material are actually thermal control problems. If you have a reference that resists you, tell us the material, thickness and geometry of the circuit and we will tell you what we would do.

Check out our range of industrial temperature control units or talk to a technician.

Real case: thermal optimisation in plastic injection moulding, with the figures from a specific process.

The material is changing: more and more recycled content

Regulation, brands' recycled content targets, and the cost and CO2 footprint of virgin resin push regrind and PCR (post-consumer recycling) toward more and more molded parts. The circular economy has ceased to be an option for the future and has become a manufacturing condition in many sectors.

Recycling is variable

A reprocessed polymer has shorter chains and comes from mixed sources. That is why its fluidity, humidity and cleanliness change from batch to batch. Where virgin resin is constant, recycling is not: each batch can behave differently inside the mold.

The consequence: a narrower process window

With variable fluidity, the adjustments that produce a good part fall within a smaller range. The good part window narrows and the process goes to the limit much faster: what worked in one batch may fail in the next.

Why mold temperature is the lever

When the material varies, mold temperature is the lever that keeps filling, finishing and shrinkage under control:

• Filling: A higher, more stable mold temperature helps a lower flow recycle fill the cavity well.
• Surface Finish: Mold temperature sets the gloss, weld lines, and skin quality of the part.
• Warping and dimensions: uniform cooling keeps a material that is inherently variable dimensionally stable.

If the temperature gets out of control, each batch ends up in scrap

If mold temperature is laxly maintained, material variability lands directly on the part and in the scrap bin: incomplete parts, warping, dimensional drift, surface defects, and unstable cycling. With recycling, loose control pays off batch by batch.

Four things to stay in control

It is not about applying more temperature, but about controlling it better. To process recycling with guarantees, four things are necessary:

• Stable and precise temperature: hold the set firmly, batch after batch.
• Recipe by material: save and recover settings when the game changes.
• Uniformity per circuit: a balanced flow so that the entire mold cools equally, with multi-circuit distribution.
• Data to see the drift: differential temperature (ΔT), flow and trends to detect material changes in time.

How MARSE controls it

With a single temperature control unit prepared for any material:

• PID with autotuning and ramps: stable and repeatable mold temperature.
• Recipes and data, with 7-inch touch screen: change material batches in seconds.
• Flow monitoring per circuit: uniform temperature throughout the mold.
• Water and oil up to 300 °C: a single platform for any recycling.
• Industry 4.0: OPC UA and Profinet, with traceability.

In short: recycling is another material

Recycling does not lower quality; an unstable temperature lowers it. Control the mold and the recycled content becomes a material like any other: repeatable, qualifyable and profitable. At MARSE we have been designing the thermal control that makes this possible since 1978.

Frequently asked questions

Does recycled plastic give poorer piece quality?

Not necessarily. What lowers the quality is an unstable temperature, not the material itself. With precise thermal control of the mold, the recycled material behaves like any other material and produces repeatable parts.

Why does recycled material narrow the process window?

Because its fluidity, humidity and cleanliness vary from batch to batch. The adjustments that produce a good piece are within a smaller margin, so the process goes to the limit more easily.

What role does mold temperature play when processing recycling?

It is the main lever: it controls the filling (it helps a less fluid recycle fill the cavity), the surface finish and the dimensional stability of the part.

What does a temperature control unit need to process recycling with guarantees?

Stable and accurate temperature, recipes per material, flow uniformity per circuit and data (ΔT and flow rate) to detect material drift in time.

What MARSE equipment is it controlled with?

With a temperature control unit with PID and auto-adjustment, recipes and touch screen, flow monitoring per circuit, water and oil up to 300 °C and Industry 4.0 (OPC UA and Profinet).

Real case: thermal optimisation in plastic injection moulding, with the figures from a specific process.

The limit that cannot be seen: the maximum allowable pressure

Jacketed and glass reactors have a maximum allowable pressure in the jacket. Exceeding it, even for a moment, can damage the coating or the shirt itself. The limit is not set by the process: it is set by the container. And that limit is non-negotiable.

Where does that pressure come from? It is set by the temperature control unit

In these systems, a thermal fluid is pumped through the jacket from a temperature control unit (the temperaturer or TCU). The pressure seen by the reactor is the sum of three factors: the pump drive, the resistance to the passage of the fluid through the circuit and the thermal expansion of the fluid when heated. In other words: the temperature control unit not only sets the temperature of the process, it also sets the pressure at which the reactor works.

The danger is dynamic: be careful with the spikes

In stable regime, staying below the limit is easy. The problem is the transients. A sudden closing of a valve, a pump starting at full power or a cold and viscous fluid can cause a pressure peak well above the stable value. And to compromise the reactor, just one moment above the limit is enough.

What overpressure costs

A single overpressure can be very expensive:

• Cracked liner: glass reactors fail under overpressure.
• Jacket leak: deformed welds and escaping thermal fluid.
• Lost batch: scrap, contamination and reprocessing.
• Production stoppage: repair, requalification and lost production.

A damaged container costs much more than the control system that would have protected it.

The balance: sufficient flow, within limits

Here is the real challenge. Flow rate is needed to transfer heat efficiently, but the pressure must remain below the reactor limit. Low flow means poor heat transfer; too much pressure, reactor at risk. The system has to sustain both conditions at the same time and stay in the safe window.

How we control it

To keep the jacket within its safe window, both in steady state and during transients, we combine several technologies that work together:

• Pump with frequency converter, regulated to a pressure setpoint.
• Expansion vessel, which absorbs thermal expansion and cushions the circuit.
• High-efficiency automatic air vents, which eliminate gas pockets that destabilize pressure.
• Pre-set static pressure: the circuit is loaded at a defined static pressure.

Depending on the process, the solution can rely on pressurised water or in high temperature thermal oil.

Regulate the pump by pressure, not by flow

The same pump can be regulated in four ways: by pressure, by flow, by ΔT (the difference between flow and return) or at a fixed percentage of speed. For a pressure sensitive reactor the choice is clear: regulate the pump by pressure. Thus the system protects the container first, without sacrificing process control.

The result: protected reactor, batch after batch

With this approach, the reactor is protected in each batch, the temperature remains stable at its setpoint, the batches are repeatable and qualifiable, and the useful life of the reactor is lengthened. It stops being a variable and becomes a certainty.

In short: control both, pressure and temperature

A pressure-sensitive reactor demands both at once: precise temperature control for the process and pressure held below the vessel limit. The right thermal system delivers both, with no compromises. At MARSE we have been designing temperature control units for reactors in chemistry and pharmaceuticals that do exactly that.

Frequently asked questions

Why is the pressure in a jacketed reactor dangerous?

Because the jacket (and, in glass reactors, the lining) has a maximum allowable pressure. Exceeding it can crack the glass or warp the jacket, damaging the container, not just the batch.

Where does the pressure in the shirt come from?

From the combination of the pump drive, the resistance of the circuit and the thermal expansion of the fluid. The temperature control unit that circulates the fluid is what, in practice, sets that pressure.

What causes pressure spikes?

Transients such as the sudden closing of a valve, the pump starting at full power or a cold and viscous fluid. An instant above the limit is enough to cause damage.

How do you control pressure without losing heat transfer?

Keeping the system in a safe window: enough flow to transfer heat, but with the pressure below the limit. It is achieved with a pressure-regulated pump, expansion vessel, automatic drains and a defined static pressure.

Why regulate the pump by pressure and not by flow?

Because in a pressure-sensitive reactor the priority is to protect the vessel. Regulating by pressure, the system adjusts the pump to never exceed the limit, while maintaining control of the process.

MARCH announces his participation in the 30th edition of Fakuma, the leading international fair in plastics processing. Of the October 12-16, 2026, we will be in Friedrichshafen (Alemania) to present our most advanced solutions in industrial thermal management.

Consolidated Experience and Global Reach

With more than 45 years of history since our founding in 1978, MARSE has become a global benchmark in the sector. Our presence at more than 70 countries and the success of more than 80,000 projects carried out back our ability to solve the most complex thermal challenges in industry today.

Innovation in Industrial Temperature Equipment

At Fakuma 2026 we will be showing our specialisation in heat transfer systems, designed to guarantee maximum stability in injection and extrusion processes:

• Water Temperators: Deposit units with range up to 90 °C and pressurized equipment for high temperature applications up to 180 °C.

• Oil Temperature Control Units: Deposit systems operational until 150 °C and closed loop solutions for demanding industrial processes up to 300 °C.

   

• Special Designs: Engineering capability to develop custom units on technical request.

   

Comprehensive Solutions for the Production Plant

Beyond temperature control, MARSE offers a full range of ancillary equipment to optimise every stage of materials processing:

• Flow Management: Multi-circuit distribution systems and high-precision flow meters.

   

• Process Peripherals: Loaders, volumetric dosing units, safety magnets and dehumidifying systems.

   

• Refrigeration: Process chillers with high energy efficiency.

   

Commitment to Efficiency and Industry 4.0

At the range SMART SERIES will be the star of our stand in Friedrichshafen. These units are prepared for smart factory, allowing constant remote monitoring and full integration into plant control systems, which translates into a significant reduction in cycle times and an improvement in the quality of the final product.

📍 Visit us in Germany: Friedrichshafen – Fakuma 2026.

MARSE at trade fairs: Plastic Pole 2026, Elmia Polymer 2026, Equiplast 2026 and K 2025 Düsseldorf.

MARCH confirms your participation in Equiplast Barcelona, the benchmark event for the plastics and rubber industry. With a track record going back to our founded in 1978 , we bring the experience of more than 80,000 projects carried out and a consolidated presence in more than 70 countries.

Leadership in Industrial Temperature Control

At our Equiplast stand we will present advanced heat transfer solutions designed to optimise efficiency in injection and extrusion processes. Our range includes:

• Water Systems: Deposit units up to 90 °C and pressurized systems that reach 180 °C

• Oil Systems: Deposit equipment up to 150 °C and high-performance closed circuits up to 300 °C

• Special Units: Custom manufacturing on request for specific technical requirements.

   

Complete Solutions for Plastics Transformation

Beyond temperature control, MARSE distinguishes itself by offering complete solutions integrating every ancillary unit needed for high-quality production:

• Fluid Management: Temperature control units, process chillers and multi-circuit flow distribution systems with precision flow meters.

• Material Treatment: Dehumidifiers, loaders and volumetric dosing units for flawless raw-material handling.

• Safety and Cleanliness: Magnet systems to protect moulds and screws.

Towards Industry 4.0 with the SMART SERIES

Our range SMART SERIES will star at the show, demonstrating how advanced connectivity and remote monitoring can dramatically reduce cycle times and energy consumption. Combining our historical experience with the latest digital technology allows us to offer systems that guarantee complete thermal stability.

📍 Visit us in Barcelona: Equiplast 2026.

MARSE at trade fairs: Fakuma 2026, Plastic Pole 2026, Elmia Polymer 2026 and K 2025 Düsseldorf.

In the dynamic polymer processing sector, efficiency is not just a goal; It is the basis of business survival. Since our founding in 1978, in Marse We have evolved together with the industry, understanding that the key to a perfect part does not lie solely in the injection pressure, but in the mold thermal stability.

Historically, cooling has been the silent “bottleneck.” Today, with the integration of the Industry 4.0, we have transformed this challenge into a measurable competitive advantage.

The Impact of Cooldown: 80% of Your Success

It is a fundamental technical data: the cooling phase represents between the 60% and 80% of the total production cycle time. This means that any improvement at this stage has an exponential impact on the plant's output capacity.

The Dangers of Operating with Obsolete Systems

Working with poor thermal control or “uncontrolled cooling” generates a series of inefficiencies that weigh down the bottom line:

• High Scrap Rates: Scrap levels between 5% and 10% due to dimensional or aesthetic errors.
• Slow Production Cycles: Unnecessarily extended cooling phases that reduce hourly productivity
• Premature Wear: Mold fatigue is accelerated by sudden changes in temperature.
• Inconsistency between Lots: Quality problems that prevent maintaining a uniform standard (Batch-to-Batch Inconsistency).

Innovation with Purpose: The Marse SMART Series

Our series SMART has been designed to eradicate these inefficiencies through a constant flow architecture and ultra-precise temperature control of ±0.1°C.

High Performance Technical Specifications

Our equipment not only cools; They manage energy intelligently:

• Thermal Range: Versatile operation between 25°C y 100°C.
• PID Accuracy: Total stability with maximum variations of ±0.1°C.
• Total Connectivity: Protocol Support Profinet y Modbus for real-time monitoring.
• Plant Capacity: Ability to manage up to 24 control units (TCUs) simultaneously.
• Agile Installation: Complete implementation in less than one work shift to minimize downtime.

Results that Transform the Plant: The Case Study

The implementation of our technology in real production environments has provided data that validates the investment in thermal control technology:

"The scrap problem during start-up alone covered the cost of the first three units in a few months. The gains in cycle time were the long-term victory".

Comprehensive Solutions for Technical Injection

In Marse, our vision goes beyond an individual team. We offer a complete ecosystem to ensure that material arrives and is processed in optimal conditions:

1. Drying and Dehumidification Systems: Crucial to avoid hydrolysis and ensure the mechanical integrity of the piece.
2. Precision Dosing Systems: To ensure homogeneity of color and polymer properties.
3. Advanced Thermal Control: The core of our specialization to ensure consistent cycles, always.

Frequently asked questions

Why is mold temperature control so decisive in injection?

Because the cooling phase concentrates most of the cycle time and determines the quality of the part. A mold with stable temperature reduces warping, rejection and differences between cavities. More information about temperature control units for injection molds.

What is ΔT and how does it affect the injection process?

It is the temperature difference between the entry and exit of the fluid in the mold. High ΔT causes uneven cooling and inconsistent parts; keeping it low and stable improves repeatability. We detail it in ΔT control.

How much can good thermal control improve profitability?

By shortening the cycle time and reducing the rejection rate, the effect on productivity and cost per part is direct. A precise temperature control unit pays for itself if you look at the total cost of ownership (TCO).

Which MARSE equipment is suitable for technical injection?

At the range of industrial temperature control units covers everything from water to high temperature oil, with precision control for each type of mold and material. Our technical team helps size the solution.

Is your process optimized for the future?

Modern manufacturing does not forgive inefficiency. If your goal is to reduce costs, improve quality and move towards more sustainable production, technology Marse It is your best ally.

Link to our brochure: Injection Molding Case Study

If the process calls for oil: open-tank oil temperature control unit, and the comparison in water or oil: how to choose.