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Home / How to Ensure Scale-Free Operation in Hard Water Areas with Water-Type Mould Temperature Controllers？

How to Ensure Scale-Free Operation in Hard Water Areas with Water-Type Mould Temperature Controllers？

2025/06/27 By Topstar

Water-Type Mould Temperature Controllers 1-1

Using a mould temperature controller in areas with poor water quality can cause scaling on heaters and internal channels, significantly reducing heat transfer efficiency and resulting in uneven mould temperatures, extended cycle times, and costly downtime. Therefore, achieving scale-free operation in these areas is not only an added advantage but also a prerequisite for continuous, high-precision manufacturing. To address such issues and ensure scale-free operation in areas with hard water, we offer the Pure Water series of water-type mould temperature controllers, as well as methods such as utilising Teflon floats, upgrading copper heaters, and enhancing circulation efficiency to ensure scale-free operation.

Water-Type Mould Temperature Controllers using pure water closed loop circulation

To prevent scaling, the Pure Water series of water-type mould temperature controllers utilises a fully closed circulation system, which is filled with pure deionised water during the circulation process. First, technicians inject deionized water into a sealed container to eliminate mineral ions. Then, the system circulates this clean medium through the mould, heat exchanger, and finally back to the integrated water tank without exposing the internal channels to untreated tap water. By isolating the circulation from the external water source, we can protect the mould from metal ion corrosion, eliminate scaling, and maintain clean flow channels. At the same time, during the installation, we will insist that all installations follow this protocol to ensure that the moulds and controllers remain rust-free and scale-free, thereby eliminating temperature drift and pressure loss during long-term production.

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Add Teflon floats to adapt to poor water quality.

In the mould temperature controller, we have added a liquid-level detection function. The use of Teflon floats can prevent oil, water, iron filings and liquids containing sediment from adhering to the floats by using its non-stick properties, thereby ensuring accurate liquid level sensing without causing mechanical wear. In addition, the chemical inertness of Teflon enables it to operate in chemically corrosive or contaminated water without any degradation or reaction with additives. Customers in areas with poor water quality, such as the UK, will opt for mould temperature controllers equipped with Teflon floats to ensure that the floats remain reliable even in challenging water supply conditions, thereby preventing pumps from running dry or overflowing. This simple and effective solution significantly reduces maintenance interventions and extends maintenance intervals.

Upgrade the copper heater of the water-type mould temperature controllers to improve circulation efficiency.

In the water-type mould temperature controller, we have also upgraded the copper heating elements with a special anti-fouling surface treatment. Copper’s excellent ductility and high thermal conductivity ensure that heat is transferred quickly and evenly to the circulating medium. As a result, the system can reach the temperature setpoint faster, reducing preheating time by 15% and improving cycle consistency. Impurities in hard water are less likely to adhere to treated copper than to stainless steel, thereby minimising scale formation. In production R&D experiments, this copper heater has been proven to extend service life by 40% in a 1,000-hour accelerated ageing test and maintain a 10% higher heating efficiency, demonstrating its advantages in demanding moulding processes where temperature accuracy is critical.

Nickel-plated copper heater

Integrated water tank reduces water quality requirements.

A key design feature of the Topstar water-type mould temperature controller is the built-in water tank that holds precisely metered pure water. In addition to simplifying installation without the need for external water supply pipes, the integrated water tank stabilises the circulation pressure and water volume, ensuring that the coolant continues to flow through the mould consistently. Therefore, since the sealed system eliminates hard water replenishment, it dramatically lowers on-site water quality requirements. Meanwhile, I configured an automatic water replenishment loop for our mould temperature controllers, introducing pre-filtered water only when necessary, thus maintaining water purity at all times and reducing maintenance burdens. This design choice prevents air entrapment, stabilizes thermal response, and prolongs pump life.

Maintenance Ensures Reliability at the Production Site

Proactive maintenance also improves the reliability of mould temperature controllers. Operators should inspect water tanks quarterly for discolouration, microbial growth, or conductivity spikes. Additionally, technicians replace filters on a strict schedule, and conductivity probes verify water integrity. Our training services team utilises hardness testers and digital conductivity testers to verify water quality, recording each measurement in our centralised maintenance database. This rigorous approach ensures that each controller operates to specification, prevents unexpected thermal cutouts or pump failures due to scaling or corrosion, and supports uninterrupted production in remote or challenging environments.

Ensure scale-free operation in areas with hard water

Teflon floats in the temperature controller for reliable level sensing, upgraded copper heaters for superior heat transfer, sealed deionised water circuits to prevent mineral deposits, integrated water tanks in water-type mould temperature controllers to stabilise water volume, and a strict maintenance regimen for continued protection. By implementing these combined solutions, you can prevent mould and rust, maintain precise thermal stability, and mitigate the effects of poor water quality.

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