Two injection moulding cells can run with the same temperature control unit and still produce different parts. It is hardly ever the temperature control unit's fault. The difference lies in what happens between the TCU and the multi-cavity mould: how the flow is distributed across the cooling circuits.
Multi-cavity moulds: the advantage of measuring the flow in every circuit
In a multi-cavity mould, every cooling circuit has its own length, its own bends and its own hydraulic resistance. When the flow rate in each one is measured and balanced, every cavity gets what it needs and no single cavity dictates the cycle for the rest.
- Identical cavities: the same flow rate and the same temperature in every circuit produce identical parts.
- A shorter, more stable cycle: no slow cavity sets the cycle time for the whole mould.
- Fewer rejects: a circuit running short of flow is spotted on screen, not in the part.
- Lower consumption: segmented control can reduce energy use by up to 30%.
The solution: electronic multi-circuit distribution
Our electronic multi-circuit distribution is installed between the temperature control unit and the mould, turning blind distribution into controlled distribution:
- Flow rate, temperature and pressure measured in every circuit, on both supply and return.
- From 2 to 12 zones per unit, in a modular format.
- Manual valves or automatic proportional control (Flow PV).
- 7″ touchscreen with alarms, data logging and mould-specific recipes.
- Synchronised with your MARSE temperature control unit.
And if you prefer a visual reading, without electronics
For anyone looking for a simple check, our WFR flowmeters provide a rotameter and a thermometer on every circuit, with manual control valves to balance each zone by hand. The EWFR adds a 7″ display and alarms, and the RWFR reaches up to 160 °C for closed circuits.
Before and after: a real installation
The images show a real installation before and after the work: on one side, tangled hoses of every length; on the other, short lines of equal length, with supply in red, return in blue and the distribution unit mounted directly on the mould. Every circuit follows the same path, and flow rate and temperature can be read circuit by circuit.
The temperature control unit and the installation, from the same manufacturer
A good temperature control unit can only perform as well as the installation behind it. That is why, at MARSE, we supply both – the industrial temperature control unit and the distribution to every cavity – and we measure the result.
FAQs
Why does a multi-cavity mould produce different parts with the same temperature control unit?
Because every cooling circuit has its own length, bends and hydraulic resistance. If they are all fed from a passive manifold, the flow is split unevenly, and the cavity that receives the least flow dictates the cycle time and reject rate of the whole mould.
How is the flow rate balanced on each circuit?
With multi-circuit distribution that measures flow rate, temperature and pressure on every circuit and lets you adjust it with manual valves or automatic proportional control (Flow PV).
What is the difference between electronic multi-circuit distribution and WFR flowmeters?
Electronic distribution measures and logs the data for every circuit on a 7″ touchscreen with alarms and recipes per mould. WFR flowmeters give a visual reading with no electronics, using a rotameter and a thermometer on each circuit; the EWFR adds a display and alarms, and the RWFR goes up to 160 °C.
How many zones does one distribution unit control?
From 2 to 12 zones per unit, in a modular format.
To find out more about flow distribution in a multi-cavity mould:
- MARSE electronic multi-circuit distribution
- MARSE industrial flowmeters
- MARSE multi-circuit technology
- MARSE temperature control units for injection moulds
- One manifold, zero control: why a passive manifold is not enough to cool the mould
Would you like us to review your mould installation? Contact us or email us at marse@marse.es.