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How to achieve precise temperature control in the 5-35℃ range on a water chiller?

2026/01/08 By le zhan

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Precise temperature control is the key to high-quality plastic products. When the cooling system can accurately control the water temperature within the set range, manufacturers can reduce defects, achieve better surface finish, and maintain more stable production cycles. Achieving this reliability doesn’t rely solely on a single component, but rather on the integrated use of refrigeration design, computer controllers, and a well-designed hydraulic system. Topstar’s water chiller and air-cooled chillers both utilize fully computerized temperature controllers for easy operation and precise water temperature control within 5-35℃, and both employ advanced refrigeration circuit designs. This improves product surface finish, prevents overheating-related defects, and ultimately enhances product quality.

Why is the 5–35℃ temperature range important?

Temperature is crucial because the performance of polymers and the thermal balance of the mold are closely related to temperature. Within the 5–35℃ temperature range, the melt cooling rate, crystallization process, and dimensional stability can be controlled. For many thermoplastics and molds, this temperature range balances processing speed and part quality: lower temperatures (closer to 5℃) can accelerate solidification and improve surface finish; higher temperatures (closer to 35℃) can reduce thermal shock and improve surface gloss for specific materials.

First, the water chiller removes heat from a closed-loop circulating fluid. The heat load fluctuates with cycle time, injection volume, and ambient conditions. Therefore, chiller selection must consider not only the peak heat load but also the dynamic response—the speed at which the temperature returns to the set point after a step change in temperature. Second, stability is as important as low temperature. A system with temperature fluctuations of ±2℃ will produce more rejects than a system with temperature stability of ±0.2℃. A properly selected chiller can meet these requirements by providing the appropriate temperature range (5-35℃) and accuracy.

Injection mold temperature

Water Chiller Refrigeration Circuit Design and Its Importance

Precise cooling begins with the refrigeration circuit. A robust design minimizes temperature drift and improves temperature recovery after load peaks. Key elements include compressor selection, evaporator size, expansion device accuracy, and condenser efficiency. Variable-frequency compressors provide variable cooling capacity, allowing the refrigeration system to adjust in small increments. This avoids frequent starts and stops, reduces temperature overshoot, and improves long-term operational stability. Multi-stage or cascaded compressor configurations provide similar advantages in large-capacity units by enabling coarse- and fine-cooling capacity matching.

Furthermore, the condenser design (air-cooled or water-cooled) must account for ambient temperature variations. Topstar offers both air-cooled and water-cooled configurations, each with its own advantages: air-cooled chillers reduce facility water consumption but require adequate airflow and clean condenser surfaces; water-cooled chillers, with sufficient hot water discharge, provide high efficiency and stable condensing temperatures. Finally, refrigeration circuit protection devices—including high- and low-pressure switches, oil management systems, and low-temperature defrost logic—ensure reliability. Topstar’s advanced refrigeration design reduces setpoint drift and enables precise control across the entire 5–35℃ temperature range.

Water Chillers with Fully Computerized Temperature Control Systems

The control strategy is central to achieving precise temperature regulation. Both Topstar’s water-cooled and air-cooled models use fully computerized temperature controllers that integrate sensor inputs, PID control, safety interlocks, and a user interface. These controllers translate measurements into actions—adjusting compressor, expansion valve, and pump speeds to maintain the set temperature.

PID control remains the benchmark, and proper tuning can reduce errors. In addition, advanced controllers add feedforward control capabilities to anticipate load changes. For example, if the injection pressure signals heating or the pump flow increases, the controller can preemptively reduce compressor capacity to minimize deviations. Adaptive control features can also adjust PID parameters in real-time based on system dynamics. Meanwhile, the user interface in Topstar’s chiller series provides clear setpoint input, trend display, data logging, and alarm notifications to expedite troubleshooting.

Water Chillers with Fully Computerized Temperature Control Systems

High-Precision Water Chiller Hydraulic Systems and Accessories

The hydraulic system determines how temperature control is implemented in the process. Even the best refrigeration circuit cannot maintain precise part temperatures when flow is unstable or heat transfer is poor. Key hydraulic components include the circulation pump, flow measurement and control, buffer tank, and heat exchanger selection.

The pump selection must meet the required flow rate and head while minimizing pulsation and cavitation. Topstar’s water chillers use a self-developed horizontal multi-stage centrifugal pump, providing multi-stage pressurization, high flow rates, and low noise, thereby improving the equipment’s cooling performance. In addition, water quality and additives are crucial. At low operating temperatures near 5℃, an ethylene glycol mixture should be used to prevent exposed pipes from freezing and to ensure the presence of corrosion inhibitors and microbial control agents.

Installation and commissioning ensure reliable operation performance between 5–35℃.

Even a perfectly designed chiller unit will suffer performance degradation if improperly installed. Commissioning aims to ensure the system performs to specifications under actual operating conditions. First, ensure proper site selection: air-cooled chillers require unobstructed airflow and sufficient clearance; water-cooled condensers require a reliable cooling water supply and appropriate water treatment.

During installation, check the refrigerant circuit for leaks, confirm the refrigerant charge, verify power and grounding, and install sensors in the recommended locations. Use vibration isolation pads to protect the compressor and pump, reducing noise and preventing mechanical vibration-induced sensor errors. Commissioning tests should include steady-state and transient evaluations. Check the equipment’s ability to maintain temperatures of 5℃ and 35℃ under controlled load. Then, set up alarms and interlocks and record initial PID parameters, sensor calibration data, and baseline performance indicators.

Providing precise temperature control

Both Topstar’s water chiller and air-cooled chillers utilize a fully computerized temperature controller for easy operation and precise control of water temperature between 5-35℃, and both employ advanced refrigeration circuit designs. Furthermore, ultra-low temperature chillers can reach temperatures below -10℃. This can better improve the surface finish of products, avoid defects caused by material overheating, and thus improve product quality. Finally, regular professional maintenance is essential to keep the system within the target accuracy range of ±0.1–0.5℃.

 

 

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