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Home / What is the thermal media compatibility of the mould temperature controller?

What is the thermal media compatibility of the mould temperature controller?

2025/05/28 By Topstar

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Choosing the right thermal media when using a mould temperature controller can also impact the accuracy of the final injection moulding process. Of course, not all fluids provide optimal performance across the entire operating range. Topstar mould temperature controllers are compatible with both clean and purified water, ensuring flexibility and reliability in various industrial environments. Clean water, typically tap water that has been treated to remove large particles, is an economical choice for general-purpose cooling. However, the mineral content in clean water can cause scale buildup and corrosion over time, increasing maintenance requirements and reducing heat transfer efficiency. In contrast, purified water removes metal ions, virtually eliminating the risk of scale formation and corrosion. Therefore, we will discuss how the selection of thermal media affects the long-term performance of the mould temperature controller.

Considerations for mould temperature controller when using clean water

When using clean water in a mould temperature controller, you can benefit from its easy availability and low cost. Clean water is typically tap water that has been filtered to remove suspended solids and is suitable for medium-speed production lines. Topstar mould temperature controllers feature corrosion-resistant stainless steel heat exchangers and large-capacity filters to capture particulate matter before it enters the circulation pump, ensuring optimal performance. However, hard water with a high calcium and magnesium content can form scale on heat transfer surfaces, reducing thermal conductivity by up to 30% over the course of months of operation. To mitigate this, we recommend regular maintenance, monthly filter replacement, quarterly water hardness analysis, and semi-annual descaling with a weak acid solution. This way, the system maintains consistent temperature control without causing extensive downtime or equipment wear.

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Pure Water Advantages and System Design

For industries that require the highest thermal stability and lowest maintenance requirements, Topstar offers a dedicated pure water series of mould temperature controllers. Pure water is processed by reverse osmosis, deionization, or distillation to nearly remove dissolved ions, thereby reducing the likelihood of scaling and electrochemical corrosion of metal parts. The pure water mould temperature controller features a water tank with a closed circulation system constructed from fully welded stainless steel to prevent air pollutants and microbial growth.

The float, seal and valve components are made of Teflon material to ensure chemical compatibility and long-term reliability, even if pure water precipitates ions from metals. Sensors continuously monitor the purity and conductivity of water in real time, alerting operators when water quality deteriorates. With an integrated water tank for easy water addition and minimal contact, the compatibility of the Pure Water Series mould temperature controllers provides better longevity and performance in high-precision moulding environments.

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Closed-loop circulation and corrosion protection of the mould temperature controller

A key feature of pure water mould temperature controllers is their closed-loop circulation system, which protects equipment and moulds from corrosive elements. In closed-loop operation, the system continuously circulates the same pure water between the temperature controller and the mould-cooling water channel without contacting external pipes or water sources. This design prevents metal ions and chlorine, commonly found in tap water from entering the loop. At the same time, the closed-loop circuit contains a vacuum degasser to remove dissolved gases, further inhibiting oxidation and microbial proliferation. Additionally, a deoxygenated resin bed in the tank effectively reduces the residual dissolved oxygen. By closing the loop circulation system and maintaining a controlled environment, pure water mould temperature controllers can eliminate electrochemical corrosion, extend the service life of pumps and heat exchangers by up to 50%, and ensure a stable heat transfer rate.

Temperature control accuracy and fluid properties

The characteristics of the thermal medium, including specific heat capacity, thermal conductivity, and viscosity, will directly affect the accuracy of the mould temperature controller. Clean water has a high specific heat capacity (4.18 J/g·K) and excellent thermal conductivity (0.6 W/m·K), with a fast response time that varies slightly depending on the type of dissolved salt. Purified water has a somewhat higher specific heat capacity, a lower freezing point, and more stable performance at set points below ambient temperature. Topstar mould temperature controllers utilise PID algorithms specifically tuned for the selected fluid to dynamically adjust the heating and cooling cycles. Flow sensors and adjustable-speed circulation pumps maintain optimal fluid velocity to prevent hot spots and ensure uniform temperature distribution. Engineers can achieve temperature stability within ±0.1°C—even with rapid load changes—by calibrating control parameters to the selected thermal medium, meeting the accuracy required for thin-wall, multi-cavity, and micro-mould applications.

Installation, safety and environmental impact

Installing mould temperature controllers that are compatible with pure water requires additional considerations to maintain water quality and system integrity. We provide complete installation recommendations, including pre-treatment equipment, for on-site delivery of pure water. The design of dedicated venting and overflow control systems meets Occupational Safety and Health Administration (OSHA) regulations for the safe handling of hot fluids. For the clean water model, the installation includes a softener and sediment filter to control hardness and particulate matter. In our eco-design, we minimize water consumption through a built-in energy-saving mode that reduces cooling water flow during periods of low load. Both the Clean Water and Pure Water series meet CE and UL safety standards, featuring over-temperature protection, low-water-level sensors, and time-on/off functions. Integrating safety and environmental control into its mould temperature controller platform ensures that any manufacturing plant can operate in a compliant and sustainable manner.

Compatibility to meet different thermal media

Whether it is clean water or high-precision, low-maintenance purified water, it determines the results of your short-term and long-term operation. Topstar’s dual-compatible approach to mould temperature controllers, with PTFE floats, robust clean water filtration systems, closed-loop circulation to prevent corrosion, and advanced PID control that adjusts according to fluid characteristics, brings flexibility. Allowing manufacturers to optimize production line efficiency and reduce maintenance costs.

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