This is how many moulds are still cooled today: nine supply lines leave a red block and nine returns enter a blue block. The temperature control unit pushes the flow in and, from that point on, nobody knows how much reaches each cavity. With mould flow control, every circuit is measured and balanced.
What you gain by measuring every circuit
A passive manifold distributes the flow, but tells you nothing about how it does so. Replace it with a system that measures every circuit and you gain four things:
- Knowing how much flow each circuit receives: a cavity running short of flow no longer goes unnoticed.
- Balancing the mould with data: flow is distributed according to what each cavity needs, not according to the length of each hose.
- Detecting a clogging circuit early: limescale and dirt show up on the screen before they show up in the rejects.
- Traceability and diagnostics: data for every circuit, so you know what has happened in the process.
To find out more about how circuits become clogged, read this article: Limescale and deposits in the mould circuit: how to avoid them
Mould flow control with MARSE: from blind distribution to controlled distribution
MARSE flow monitoring goes exactly where the manifold used to be, between the temperature control unit and the mould:
- Flow rate, temperature and pressure measured in every circuit.
- Manual or proportional valves to bring each circuit to its target flow rate.
- 7″ touchscreen with alarms, data logging and mould-specific recipes.
- From 2 to 12 zones per unit, synchronised with your MARSE temperature control unit.
Before and after on a real mould
In the installation shown, the passive manifold has been replaced by a MARSE Flow Basic mounted directly on the mould: nine circuits, each with its own valve and labelled line. Every circuit is balanced to its own flow rate.
The result: identical cavities, a faster and more stable cycle, faults detected before they reach the part, and up to 30% lower energy consumption.
A manifold distributes the flow. Flow monitoring tells you where it goes.
FAQs
Why is a passive manifold not enough to cool the mould?
Because it splits the flow according to the length and resistance of each hose, not according to what each cavity needs, and it gives no indication of how much flow reaches each circuit.
What does mould flow control measure?
Flow rate, temperature and pressure on every circuit, with alarms, data logging and recipes per mould on a 7″ touchscreen.
How do you detect a circuit that is becoming blocked?
Scale and dirt gradually reduce the flow rate in the circuit. With per-circuit measurement, that drop shows up on the screen before it shows up in the rejects.
How much energy can be saved?
With the flow rate balanced on every circuit, energy consumption can be up to 30% lower.
To find out more about flow monitoring on the mould:
- MARSE electronic multi-circuit distribution
- MARSE industrial flowmeters
- MARSE multi-circuit technology
- Same temperature control unit, different part: before and after the installation of a multi-cavity mould
Does your mould have one circuit calling the shots? Contact us or email us at marse@marse.es.