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Home / Technical Features Regarding the Corrosion Resistance of the Topstar Injection Molding Chiller Series

Technical Features Regarding the Corrosion Resistance of the Topstar Injection Molding Chiller Series

2026/10/23 By le zhan

Technical Features Regarding the Corrosion Resistance of the Topstar Injection Molding Chiller Series

Corrosion resistance directly affects the service life, leak risk, and maintenance requirements of injection molding chillers. Topstar’s injection molding chiller series enhances durability through three key design features:

  1. They utilize nut-type coil connections to reduce reliance on welded refrigerant fittings and employ 2205 duplex stainless steel to enhance corrosion resistance;
  2. Selected 5 HP and 10 HP models are equipped with thickened polypropylene (PP) water tanks;
  3. For water-cooled chillers, the use of robust shell-and-tube condensers further ensures reliable heat dissipation and facilitates routine maintenance.

These features collectively address potential failures in the refrigerant and water circuits, helping manufacturers minimize downtime, maintain cooling stability during the injection molding process, and improve corrosion resistance.

How do the coil connection methods and materials in the Topstar injection molding chiller series reduce corrosion and leaks?

The refrigerant circuit is a critical component that determines a chiller’s reliability. A leak not only reduces the refrigerant charge and decreases cooling capacity but often requires professional repair. Although corrosion and joint failure are distinct issues, they can exacerbate each other: corrosion weakens component strength, while poorly designed or aged connections can become pathways for refrigerant leaks. By adopting mechanical coil connections and upgrading to stainless steel materials, Topstar has effectively reduced reliance on vulnerable joints and enhanced the equipment’s resistance to corrosive operating conditions.

Nut-type coil connections reduce the risk of refrigerant leaks

Traditional coil assemblies often use welding to connect stainless steel components to copper tubing. Because these materials have different properties, this approach often creates challenges during manufacturing and in service—especially under pressure, vibration, and frequent temperature fluctuations—where joints must remain tight and reliable at all times.

Topstar’s chiller machine uses a nut-type mechanical connection at the coil joints, replacing traditional welding between stainless steel and copper tubing. This design reduces reliance on welded joints and simplifies the connection structure. Fewer weak joints mean fewer potential points for refrigerant leaks. The nut-type connection design aims to reduce risks at connection points, not to replace standard assembly procedures and quality control.

Nut-type coil connections reduce the risk of refrigerant leaks

2205 duplex stainless steel enhances the corrosion resistance of the injection mold chiller series

Material selection is another key factor in extending the service life of injection molding chillers. In specific coil designs, Topstar uses duplex stainless steel 2205 instead of traditional 304 or 316 stainless steel to enhance the equipment’s corrosion resistance.

Duplex stainless steel 2205 combines an austenitic and ferritic microstructure and contains alloying elements such as chromium, molybdenum, and nitrogen. These elements help improve the material’s resistance to pitting corrosion, crevice corrosion, and chloride-induced stress corrosion cracking. (According to Alleima’s technical data sheet for SAF 2205, this grade offers better overall corrosion resistance than 316L in most environments.) Compared to traditional 304L and 316L, it demonstrates significant advantages in resisting chloride-induced stress corrosion cracking.

In Topstar’s injection molding chiller series, 2205 (duplex stainless steel) offers greater resistance to specific corrosion mechanisms, helping protect the coils and prevent premature material degradation.

2205 duplex stainless steel enhances the corrosion resistance of the injection mold chiller series

How Do Topstar’s Injection Molding Chiller Series Enhance Corrosion Resistance in Water Tanks and Condensers?

Corrosion protection must extend beyond the refrigeration coils. The water circuit also affects equipment reliability because circulating water, dissolved minerals, and potential deposits constantly expose water tanks and heat exchangers to corrosive conditions. Topstar addresses these challenges through optimized material selection for small-capacity water tanks and durable heat exchanger design for water-cooled models. The optimal solution depends on the components’ operating environment: the water tank material must be compatible with expected water quality. At the same time, the condenser must withstand the cooling-water environment and allow easy inspection and cleaning.

5 HP and 10 HP Models Feature PP Tanks

In select 5 HP and 10 HP injection molding chiller models, Topstar uses thickened, eco-friendly PP tanks instead of traditional stainless steel tanks.

Although stainless steel tanks are inherently durable, their performance still depends on the water’s chemical properties, manufacturing quality, and weld integrity. If manufacturing defects, localized corrosion, or operational stress are present, the structural integrity of the welded areas may be compromised, creating a weak point.

PP tanks eliminate metal corrosion in the tank body and remove the risk of leaks caused by corrosion or stainless-steel weld failure. The reinforced structural design provides a water-storage solution that doesn’t rely on welded stainless steel tanks. For small chillers, this reduces corrosion-related maintenance and simplifies the tank structure.

5 HP and 10 HP Models Feature PP Tanks

Shell-and-Tube Condensers Enable Long-Term, Stable Operation of Water-Cooled Chillers

Topstar’s water-cooled chillers use shell-and-tube condensers, which offer a robust design, efficient heat dissipation, and easy maintenance. The heat transfer surface keeps the refrigerant circuit separate from the cooling water circuit while allowing heat to flow from the refrigerant into the external cooling water.

Shell-and-tube condensers are widely used in industrial chillers; their tube-bundle structure offers excellent heat transfer performance and facilitates maintenance. If sediment accumulates in the water-side channels, technicians can inspect and clean the tube bundle to restore heat-transfer efficiency. Topstar’s shell-and-tube design supports long-term operation and handles fluctuations in cooling water conditions better than designs that require frequent maintenance.

Shell-and-Tube Condensers Enable Long-Term, Stable Operation of Water-Cooled Chillers

Corrosion-Resistant Chillers for Various Production Environments

The corrosion-resistant technology employed in Topstar’s injection molding chiller series effectively addresses a variety of potential risks.

By connecting the coils with nuts, reliance on vulnerable welded joints is reduced; the use of 2205 duplex stainless steel enhances resistance to localized corrosion and chloride-induced corrosion; the use of PP water tanks eliminates the risk of metal corrosion in specific components; and the use of shell-and-tube condensers ensures that the equipment’s heat dissipation system is both durable and easy to maintain.

These design advantages reduce performance degradation and corrosion-related leakage risks, simplify maintenance, and provide more reliable cooling for injection molding production.

 

 

 

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