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Home / Controllable temperature range: Topstar mold temperature controller meet diverse needs

Controllable temperature range: Topstar mold temperature controller meet diverse needs

2026/01/19 By le zhan

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When stable and responsive, the part can be molded in a single cycle. Once temperature deviations occur, cycle time, part dimensions, and product yield are all affected. Topstar’s mold temperature controller combines a dedicated 7-inch touchscreen, an optimized PID algorithm that improves control efficiency by approximately 10%, and a fast-response solid-state relay with a switching speed of only 0.1 seconds, providing stable mold temperature for various injection molding applications.

Why is a controllable temperature range important in injection molding?

Mold temperature directly affects melt flow, cooling behavior, crystallinity, and surface finish. For injection molding machines, the appropriate mold temperature range varies depending on the polymer and process:

Low-temperature processes: Cooling in the 20–80°C range is usually sufficient to maintain shape and fast cycle times.

Standard thermoplastics (ABS, PP, PE): Molds typically operate at temperatures of 40–90°C, depending on wall thickness and surface finish targets.

High-performance engineering plastics (PC, PBT, PA, PET): Higher mold temperatures are required—sometimes up to 80–140°C—to minimize stress, improve surface gloss, and accelerate crystallization.

Ultra-high-temperature materials (PEEK, PPS, high-crystallinity LCP): Mould circuits capable of withstanding 200°C or higher may be required; oil-based mold temperature controllers typically offer temperature ranges up to 320°C.

A mold temperature controller with a wide, stable, and rapidly controllable range allows manufacturers to handle multiple polymers and mold types without changing equipment. This flexibility reduces capital costs and shortens mold changeover times. Furthermore, the closer the mold temperature is to the target temperature and the smaller the overshoot, the more consistent the part characteristics obtained on the injection molding machine. In other words, the wider the controllable range, the greater the process flexibility.

Why is a controllable temperature range important in injection molding

Topstar Mold Temperature Controller Touchscreen and PID Control Advantages

Topstar equips its mold temperature controllers with a dedicated 7-inch touchscreen controller designed for ease of use and precise setpoint control. The touchscreen provides operators with intuitive access to setpoints, heating curves, alarm thresholds, and historical data—crucial when running multiple moulds or balancing across various zones.

In addition to the ergonomic interface, Topstar uses an optimised PID temperature-control algorithm, resulting in approximately 10% greater temperature control efficiency than traditional methods.

The importance of PID:

Proportional control (P) reduces most of the error between the set temperature and the actual temperature.

Integral (I) corrects residual steady-state errors (offsets) that develop over time.

Derivative (D) dampens rapid changes and helps prevent overshoot.

Topstar’s optimized algorithm adapts to the thermal dynamics of specific molds/loads. This reduces overshoot during heating, shortens stabilization time, and minimizes temperature cycling that stresses the injection molding process. For example, molds with high thermal mass typically require a conservative P value and a higher I value; Topstar’s controller automatically adjusts to these dynamics, reducing the need for manual readjustment.

Practical benefits of the PID control algorithm include:

Improved temperature uniformity in the cavity and cycle, resulting in better dimensional consistency.

Reduced break-in time for new molds and faster injection molding machine qualification.

Reduced scrap and improved surface consistency in critical applications such as medical or optical parts.

Therefore, combined with the straightforward touchscreen user interface, the PID control functionality makes it easier for production line operators and engineers to set, monitor, and maintain ideal mold temperatures.

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Fast-Responding Solid-State Relays and Their Impact on Yield

Topstar mould temperature controllers use solid-state relays with a response time of only 0.1 seconds, enabling fast, smooth switching of heater loads. Unlike mechanical contactors, solid-state relays switch electronically, eliminating arcing and contact wear while significantly reducing electromagnetic noise.

In the injection molding field, these advantages translate to:

Higher effective resolution: Solid-state relays pulse the heating power in acceptable increments, supporting precise temperature control, especially for small-thermal-mass molds.

Reduced mechanical maintenance: No contact erosion means lower failure rates and reduced scheduled maintenance. Faster Corrective Actions: SSRs react within 0.1 seconds—crucial when injection molding cycles or localized exothermic events require rapid temperature correction.

Reduced Thermal Fluctuations: Finer control reduces the amplitude of temperature fluctuations, improving part quality and repeatability.

Mold Temperature Controller Integration and Digital Upgrade with Injection Molding Machines

In modern injection molding facilities, equipment integration is crucial. Topstar’s mold temperature controllers are designed for seamless integration with injection molding machines and digital systems:

Control Interoperability: The controller supports Modbus, Ethernet/IP, and other industrial protocols. This allows the controller to exchange setpoints, alarm information, and performance metrics in real time with the injection molding machine PLC and factory MES systems.

Digital Upgrade: A 7-inch touchscreen supports recipe storage and quick setpoint recall to reduce changeover time between parts or molds, especially useful when the injection molding machine runs multiple SKUs.

Data Logging and Traceability: The mold temperature controller can log temperature profiles and alarm information, aiding root cause analysis in the event of quality incidents. This data also supports compliance requirements in regulated industries.

By interconnecting mold temperature control with injection molding machine control, Topstar helps factories achieve more innovative production: synchronized startup sequences, automatic preheating curves matched to machine cycles, and coordinated alarm handling, resulting in reduced mean time to repair. Ultimately, this digital coordination helps improve yield and product reliability.

Mold Temperature Controller Integration and Digital Upgrade with Injection Molding Machines

Enhanced Safety and Energy Efficiency

Topstar incorporates safety and efficiency into its hardware and processes, as high-temperature molding circuits in injection molding present safety and energy challenges. Key features include:

Safety Features:

Independent Over-Temperature Protection: Hardware high-temperature limiters and thermal fuses cut off power to the heaters if the central control fails.

Isolated Circuits and Safety Interlocks: Protective doors, flow switches, and door interlock logic prevent the injection molding machine from operating if the thermal circuit is compromised.

Leak Detection and Alarms: Level and pressure sensors notify operators before leaks or pump failures affect components or equipment.

Energy Efficiency:

Improved PID Control Efficiency: Control efficiency is improved by 10%, reducing heater cycling and energy waste. Stable control of setpoints minimizes energy loss due to overshoot. Adaptive Heating: Controllable heating curves reduce peak power consumption while still ensuring timely mold readiness.

Thermal Insulation and Minimized Dead Volume: Well-insulated pipelines and minimized manifold volume reduce standby heat loss and improve overall system performance.

Controllable Temperature Range to Meet Diverse Needs

Topstar’s mould temperature controllers combine a 7-inch touchscreen, improved PID control, and 0.1-second SSR switching to meet the temperature requirements of various injection-moulded products. They broaden the controllable temperature range, enabling faster stabilization and more stable operation, supporting digital transformation goals, and ensuring high yields across various polymers and complex molds. With proper selection and integration, these controllers can reduce waste, improve production efficiency, and support a broader range of manufacturing applications on modern injection molding machines.

 

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