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Do different types of mold temperature controllers have an impact on injection molding machines?

2025/05/16 By Topstar

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When communicating with customers at offline exhibitions and online, they often ask us questions about the impact of various mold temperature controllers on injection molding machines. As an injection molding machine manufacturer, choosing a water type or oil type mold temperature controller can significantly affect plastic injection molding machines‘ performance and production profitability. Water type mold temperature controllers perform well in the temperature range of 120°C to 180°C, using deionized water or fast heat transfer at process temperatures. Oil type mold temperature controllers operate between 200°C and 320°C, using thermally stable heat transfer oil to withstand high-temperature applications. Either type of mold temperature controller can be connected to Topstar’s injection molding machines through a dedicated control system, and there is no communication problem between the devices.

Impact of using a water type mold temperature controller with injection molding machines

When integrated with a plastic injection molding machine, a water type mold temperature controller provides fast ramping speeds at moderate temperatures, making it the first choice for thermoplastics such as PP, PE, and ABS. Their high specific heat capacity and low fluid viscosity ensure uniform temperature distribution across the mold surface, minimizing thermal gradients that can cause warpage, sink marks, or residual stresses in the final part. At the same time, water-type temperature controllers are compatible with the control systems of Topstar injection molding machines, and the PID control of water-type temperature controllers ensures temperature stability of ±0.1°C, which is critical for delicate parts such as optical or medical housings.

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High-precision filters can simplify maintenance and regularly replace water treatment chemicals to prevent corrosion and biological growth, for operations focusing on medium and low temperature molds, such as consumer goods, toys, and automotive interior parts, water-type temperature controllers combined with plastic injection molding machines provide reliable and cost-effective performance.

Impact of using oil type temperature controllers with injection molding machines

Oil type temperature controllers are more suitable when using injection molding machines to produce PC, LCP, PEEK, and die casting processes. They can maintain mold temperatures between 200°C and 320°C, ensuring smooth melt flow, well-developed crystal structure, and excellent surface finish. At the same time, it can bring precise temperature control, rapid heating, and cooling. In addition, to ensure safe use, the oil type mold temperature controller adopts an electrical box separation design to isolate the high temperature conduction in the chassis and effectively protect the electrical components.

In addition, the problem of natural wear and leakage of the shaft seal is solved by a magnetic drive pump, and an over-temperature protection switch is standard in the motor coil to prevent the motor from overheating and burning, reduce the failure rate, and reduce the risk of accidental contact by personnel. They are usually widely used in fields requiring strict tolerances and excellent mechanical properties.

Impact on cycle time and production efficiency

The right mold temperature controller directly affects the cycle time efficiency of the injection molding machine. Water type controllers have the characteristics of rapid heat exchange, which can shorten the preheating and cooling stages of low-temperature molds by up to 20%, thereby significantly increasing the output of injection molding machines. However, due to the boiling point of water and system pressure limitations, their performance will decrease above 180°C. In contrast, oil-type controllers maintain consistent high-temperature control, prevent overcooling of critical thin-walled parts, and eliminate rework related to incomplete filling or cold materials.

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Despite slower cooling rates than water type temperature controllers, the advanced cooling circuits and heat exchangers integrated into Topstar’s temperature controllers mitigate these effects, providing balanced cycle times under various processing conditions. Actual case studies have shown that high-volume manufacturers who switch to optimized temperature controllers can reduce overall cycle times by 5-10%, directly translating into increased daily output and revenue.

Energy Consumption and Cost Considerations

Of course, energy efficiency is an area of ​​concern for any injection molding manufacturer. Water type mold temperature controllers typically consume less power when used with all electric injection molding machines, up to 15% less, because water’s higher specific heat capacity requires less energy to maintain target temperatures between 120°C and 180°C.

In contrast, oil type temperature controllers require more energy to heat and circulate the viscous oil, especially at temperatures above 250°C. However, the total cost of ownership must also consider the increased machine uptime and reduced scrap rates that oil type systems can provide in producing high-performance polymers. We advise our customers to conduct a comprehensive cost analysis and find that water type temperature controllers can achieve a quick return on investment when used with all electric injection molding machines for standard commodity plastic production. In contrast, oil type temperature controllers can maximize production and part performance for special applications, offsetting higher operating costs.

Maintenance, Safety, and Reliability

The synergy between mold temperature controllers and injection molding machines extends to strict maintenance and safety procedures. Water type mold temperature controllers require regular filter changes, coolant quality checks, and monitoring of corrosion inhibitors to prevent scale buildup and microbial growth. Oil type cooling requires regular oil sampling, particle contamination analysis, and filter changes to remove oxidation byproducts and ensure thermal stability. Topstar injection molding machines have an integrated alarm system connected to the controller sensors to automatically shut down during coolant loss, overpressure, or temperature exceedance. Our recommended maintenance intervals are once a quarter for water type mold temperature controllers and once every two years for oil type mold temperature controllers to ensure operational reliability, protect hydraulic seals, and prevent unexpected downtime.

Choose based on machine type and material.

The choice of water and oil type temperature controllers can significantly affect the performance of the injection molding machine. Water-based systems excel at low to medium temperatures (120°C to 180°C), enabling fast cycle times, reduced energy consumption, and simplified maintenance. Oil type temperature controllers provide stable high temperature control (200°C – 320°C), which is suitable for injection molding engineering polymers requiring thermal uniformity and die casting processes. We recommend that you choose based on the injection molding machine you already have, material properties, production volume, cycle time goals, and total cost of ownership goals.

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