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How do we acceptance test mould temperature controller to ensure temperature uniformity and stability?

2025/10/06 By le zhan

mould-temperature-controller（10.4）

A 1°C deviation in mould temperature isn’t just a minor flaw; it can impact the quality of the finished product. The Society of Plastics Engineers (SPE) reports that inconsistent mould heating or cooling accounts for 22% of all injection moulding defects, costing US factories tens of thousands of dollars in material waste and downtime annually, from warping automotive parts to leaking packaging. Therefore, Topstar goes beyond simply testing mould temperature controller after they’re manufactured; we put them through a three-stage acceptance process designed to eliminate risk. Before final delivery, we conduct 48 hours of continuous operation, 10,000-level statistical system testing, and two full-cycle production simulations to ensure temperature uniformity and stability.

Setting Clear Standards for Mould Temperature Controller Performance

Before any testing begins, we establish measurable benchmarks. As a mould temperature controller manufacturer, Topstar aligns your specific needs with performance metrics. For example, is your process for producing thin-walled packaging requiring a temperature uniformity of ±0.5°C, or is it for producing large structural parts with a tolerance of ±1°C? What is the target heat-up time during mould changeovers? We then cross-reference this data with industry standards to develop a customised testing plan. For example, a customer producing HDPE bottles required their mould temperature controller to maintain a temperature of 90°C with no zero drift during a 6-hour run, so we built this tolerance into the benchmark test. This upfront work ensures our testing goes beyond simply guaranteeing performance and verifying the mould temperature controller’s suitability for your workflow, rather than simply testing in a lab.

Mold Temperature Controller 9-1

48-Hour Continuous Run to Verify Mould Temperature Controller Stability

Every batch of our tested mould temperature controllers is run continuously for 48 hours to simulate the 24/7 production cycle that many plastics plants rely on. Shorter testing can miss gradual issues, such as heat exchanger performance degradation after 20 hours or electrical components causing minor temperature drift during ramp-up. During this phase, we monitor three key metrics every 5 minutes: mould inlet, outlet, and surface temperatures; heat transfer fluid pressure; and energy consumption. We recently conducted a 48-hour test for an automotive customer at 120°C for a PP part. This ensured fluctuations did not exceed ±0.3°C, well below the ±0.5°C limit, while fluid pressure remained stable and showed no signs of wear. If even the slightest temperature drift occurred in a particular unit, we paused the test to troubleshoot, fix the root cause, and restart the test.

Using 10,000-degree statistical system testing for mold temperature uniformity

Using a 10,000-degree statistical system testing for mould temperature uniformity

Uniformity, ensuring that every part of the mould maintains the target temperature, is just as important as stability. If the mould temperature controller reaches 150°C at the centre and 148°C at the edge, inconsistent parts will be produced. Therefore, we use 10,000-degree statistical system testing to collect 10,000 data points throughout the mould and fluid system to ensure consistent performance. We begin by placing 12 high-precision sensors (calibrated to ±0.1°C) in the mould cavity, fluid lines, and heating elements. Over eight hours, we recorded temperature readings every 2.88 seconds, accumulating 10,000 data points. We then used SPC to analyse variations. For example, for a medical plastics customer producing syringe barrels, testing revealed a tiny hot spot (150.7°C) that had been missed during the initial 48-hour test. We adjusted the heating element layout, retested, and achieved 99.9% of readings within ±0.3°C.

Two full-cycle simulations validated equipment readiness

Even mould temperature controllers that perform well in continuous operation need to adapt to the real-world production rhythm: heat, hold, cool, repeat. Our third phase simulated this process with two complete production cycles. Each cycle included:

  1. Heating: Ramp up from ambient to target temperature
  2. Hold: Maintain temperature for six hours (simulating a production shift)
  3. Cooling: Cool down to 40°C (for demolding or mould change)
  4. Restart: Repeat the cycle to test consistency.

We ran a 48-hour cycle for a consumer goods customer producing polypropylene bottle caps. The mould temperature controller reached 100°C in 9 minutes and maintained a uniformity of ±0.2°C. This phase ensures that the equipment is not only stable but also adaptable to fluctuations in your operations. If issues arise with heating speed or cooling efficiency, we refine the control algorithm or adjust components before continuing.

Documenting and Approving the Tested Equipment

Testing is meaningless without transparency. After completing all three phases, we compile a comprehensive report for you. We walk you through the report, answering questions like, “How did the equipment perform during the cooling phase?” or “What happens if our production run exceeds 6 hours?” Only after you approve the results do we consider the mould temperature controller “tested and ready.” For one packaging customer we worked with, this step revealed a slight deviation during the 48-hour test. We replaced a worn O-ring, retested, and shared the updated data before delivery.

Documenting and Approving the Tested Equipment

Ensuring Customer Success Through Rigorous Testing

For plastics manufacturers, reliable mould temperature controllers are the cornerstone of consistently high-quality production. Topstar’s acceptance testing includes 48 hours of continuous operation, 10,000-level statistical testing, and two full-cycle simulations—more than just a series of steps, it’s a commitment. We test our mould temperature controllers the way you use them: continuously under real-world conditions, taking your specific needs into account, ensuring continuous production.

 

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