Applications by Sector
Cooling for Plastics Industry
Chillers and temperature controllers for processing
Cooling and thermal control systems for injection molding machines, extruders, blow molders and thermoformers. Chillers from 5 to 500 TR and temperature controllers with ±0.5°C precision. Complete solutions for mold cooling, cylinders and plastics processing with maximum energy efficiency.
Talk to SpecialistTechnical Specifications
Process Requirements
Precise mold temperature control to ensure dimensional quality, surface finish and optimized cycle time. Thin-wall molds require higher precision.
Continuous barrel and die cooling to maintain proper melt viscosity. Essential for profiles, pipes and films.
Rapid parison cooling for uniform bottle or packaging formation. Cycle time depends directly on thermal efficiency.
Mold temperature control for precise plastic sheet forming. Directly affects thickness and strength of the final product.
Maintaining ideal hydraulic oil temperature for injection machines to preserve viscosity and component lifespan.
Controlled environment for raw material and finished product storage, preventing moisture absorption by polymers.
Technical Analysis
Importance of Thermal Control in Plastics Processing
The plastics processing industry is extremely sensitive to temperature variations. Each process — injection, extrusion, blow molding, or thermoforming — has specific thermal requirements that directly impact the quality of the final product, line productivity, and operational costs.
Impact of Temperature on Quality
Mold temperature directly influences several characteristics of the injected product:
- Dimensional quality: Temperature variations cause irregular contractions, resulting in parts out of specification
- Surface finish: Very cold molds generate visible flow marks and weld lines
- Internal stresses: Uneven cooling creates residual stresses that can cause warping or premature failure
- Cycle time: Optimized temperature allows faster cycles without compromising quality
Thermal Load Calculation
The correct sizing of the refrigeration system considers multiple factors:
- Mass of material processed per hour
- Polymer processing temperature
- Desired mold temperature
- System heat exchange efficiency
- Thermal losses to the environment
Helioterm performs detailed thermal load studies for each application, ensuring the optimal sizing of the system.
Centralized vs. Dedicated Systems
The choice between centralized and dedicated systems depends on several factors:
| Characteristic | Centralized System | Dedicated System |
|---|---|---|
| Initial investment | Higher, but with better cost per TR | Lower, ideal for small plants |
| Energy efficiency | Superior (economy of scale) | Good, without distribution losses |
| Redundancy | N+1 configuration available | Requires individual backup |
| Flexibility | Serves multiple machines | Operational independence |
| Maintenance | Centralized, more efficient | Distributed, without total shutdown |
Sector Challenges
Maintaining precise and uniform mold temperature is essential for dimensional quality and surface finish. Variations of just 2°C can cause scrap.
Extruders and blow molders generate intense heat that must be dissipated quickly to maintain productivity. Cooling capacity must keep up with demand peaks.
Cycle times depend directly on the cooling system efficiency of molds and equipment. Every second saved represents productivity gains.
Thermal load varies according to production mix, requiring flexible and responsive systems. Variable frequency drive systems optimize consumption.
Cooling systems represent up to 30% of plant energy consumption. High-efficiency chillers significantly reduce operational costs.
Unplanned shutdowns directly impact production and operational costs. Redundancy and predictive maintenance are essential.
Our Solutions
Centralized water cooling for multiple machines with high efficiency, N+1 redundancy and variable frequency drive control.
View ProductDedicated solution for individual machines or specific production cells, with simplified installation and independent operation.
View ProductPrecise mold temperature control with rapid heating and cooling, ideal for processes requiring temperature variation.
View ProductPrecise hot and cold water mixing for fine temperature control, with rapid response to demand variations.
View ProductHigh capacity for large plants, with continuous operation, low vibration and long service life.
View ProductCustom projects for plants with multiple machines and variable demands, including complete machine room.
View ProductRegulations and Standards
Benefits for Your Business
Success Case
Plastic Packaging Industry - São Paulo
Implementation of centralized chilled water system for 12 high-speed injection machines, replacing 15-year-old obsolete individual chillers. The project included machine room with 3 chillers of 100 TR each, pumping system with variable frequency drive and complete automation.
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