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When Should You Use a 160°C High-Temperature Mould Temperature Controller?

2026/08/28 By le zhan

When Should You Use a 160°C High-Temperature Mould Temperature Controller

For most injection moulding applications, a standard 120°C mould temperature controller provides a sufficient temperature range. However, certain engineering plastics, precision components, and injection moulding processes with extremely high quality requirements demand higher, more stable mould temperatures. In such cases, if the equipment operates near the upper temperature limit of a 120°C system, it may compromise process flexibility and temperature stability. This is where a 160°C high-temperature mould temperature controller comes in.

Specifically, you should consider using a 160°C mould temperature controller in the following situations:

  • The required mould temperature exceeds the suitable operating range of a 120°C model;
  • The processing of engineering plastics requires higher mould temperatures;
  • Surface quality, dimensional stability or filling consistency are highly dependent on mould temperature;
  • You wish to continue using water as the heat transfer medium;
  • The process does not require the higher operating temperature range offered by 180°C systems or oil-based temperature controllers.

The 160°C mould temperature controller bridges the gap between conventional water temperature control and high-temperature applications.

A 160°C high-temperature mould temperature controller should be selected when sufficient temperature headroom cannot be provided

The most direct reason for selecting a 160°C high-temperature mould temperature controller is that the required process temperature exceeds the practical operating range of conventional 120°C models.

However, this does not mean that the mould itself must operate at 160°C.

The rated temperature represents the heat transfer circuit’s maximum operating capacity. The actual mould temperature may be considerably lower. The more critical issue is whether the mould temperature controller possesses sufficient temperature headroom to maintain the required process temperature stably.

A 160°C high-temperature mould temperature controller should be selected when sufficient temperature headroom cannot be provided

Avoiding Prolonged Operation of the Mould Temperature Controller at Its Limits

Suppose a moulding process requires a higher mould temperature.

If a 120°C unit operates for an extended period close to its maximum capacity, its operational margin will prove insufficient in the following scenarios:

  • Startup with a cold mould;
  • Increased production speed;
  • Large moulds absorbing more heat;
  • Changes in cooling conditions.

A 160°C model provides additional thermal capacity, making it easier to maintain the set temperature without operating continuously near the unit’s maximum limits.

Therefore, the basic selection principle is straightforward:

Normal-temperature moulding → 120°C

Medium-to-high-temperature moulding → 160°C

Ultra-high-temperature water temperature control → 180°C

Temperatures exceeding the applicable water temperature range → Select an oil-based temperature control unit.

For engineering plastics that require higher mould temperatures

The second main application area for 160°C high-temperature mould temperature controllers is processing engineering plastics.

Certain engineering plastics require higher mould temperatures to ensure stable flow, surface reproduction, crystallisation behaviour, dimensional control or mechanical properties.

Always follow the material supplier’s processing recommendations and determine specific temperature settings in conjunction with actual moulding trials. However, when the recommended mould temperature approaches or exceeds the suitable operating range of a standard mould temperature controller, you can decide whether a 160°C model is required based on the specific mould temperature. Even with the same resin, two products may require vastly different mould temperatures because of variations in wall thickness, geometry, surface requirements, and moulding cycle conditions.

For engineering plastics that require higher mould temperatures

Select the 160°C model when raising the mould temperature helps improve filling performance

Higher mould temperatures help delay the premature solidification of molten plastic near the cavity walls. This is particularly beneficial for products featuring thin-walled sections, long flow paths, fine textures, or complex cavity geometries.

If the mould temperature is too low, the plastic may solidify before these areas fill. By controlling a higher mould temperature, the melt has more time to flow into hard-to-fill areas before solidification progresses further. Therefore, when the required temperature range exceeds what a standard 120°C system provides, a 160°C mould temperature controller ensures more stable filling results.

Selecting a 160°C High-Temperature Mould Temperature Controller When Both High-Temperature Control and a Water-Based Medium Are Required

The third key consideration when selecting a 160°C mould temperature controller relates to the heat transfer medium. Water has long been an efficient medium for mould temperature control because of its excellent heat-transfer properties. However, when operating above the boiling point at atmospheric pressure, the circulation system must maintain appropriate pressure to prevent boiling, gas accumulation, and unstable flow rates.

Conventional low-temperature mould temperature controllers cannot be directly converted into reliable high-temperature units simply by increasing the heater power.

Therefore, Topstar’s 160°C high-temperature water temperature controller employs a sealed circulation design, combining indirect cooling technology with a miniature pressurised make-up water pump. This makes the 160°C model the ideal choice for manufacturers who need a wider temperature control range while retaining the heat-transfer advantages of a water medium.

Selecting a 160°C High-Temperature Mould Temperature Controller When Both High-Temperature Control and a Water-Based Medium Are Required

Choose 160°C when ‘stable high-temperature circulation’ is more important than ‘maximum temperature’

When water temperature rises significantly, simply withstanding high temperatures is not enough. The mould temperature controller must also maintain stable circulation flow. This is a key difference between specialised 160°C high-temperature mould temperature controllers and conventional low-temperature systems. Topstar ensures stable high-temperature circulation through several specialised design features.

Design of a cooling pump for protecting the circulation system

The Topstar 160°C series utilises a pump featuring a cooling circuit in the mechanical seal area. In high-temperature environments, mechanical seals face greater thermal stress. Prolonged exposure to high temperatures accelerates wear and increases leakage risk. The cooling circuit reduces thermal stress around the seals, thereby extending the pump’s service life and maintaining circulation stability.

This is also a key difference between the Topstar 160°C and 180°C models.

The 160°C series uses a mechanically sealed pump with a cooling function, while the 180°C series uses a magnetically driven pump to handle the more demanding operating conditions at higher temperatures.

For users, this provides a clear guideline for model selection:

If the 160°C operating range meets requirements, the ‘cooled pump’ solution offers a practical balance between performance and system complexity.

Design of a cooling pump for protecting the circulation system

Gas-liquid separation design for enhanced circulation stability

High-temperature water may release dissolved gases and expand thermally. If gas remains trapped within the circulation loop, it may cause bubble formation, pressure fluctuations, and unstable heat transfer.

Consequently, Topstar employs a gravity-fed gas-liquid separator.

This separator isolates released gases from the circulating water, preventing them from re-entering the mould circuit. At the same time, it buffers volume and pressure changes caused by thermal expansion.

This results in a more stable high-temperature circulation. Other features designed to enhance reliability include:

  • Solid Teflon (PTFE) level float;
  • Integrated piping structure;
  • Specialised one-way check valve design;
  • Reduction of unnecessary connection points.

These technical features ensure that the 160°C high-temperature mould temperature controller not only reaches the set temperature but also reliably maintains it throughout continuous production.

Gas-Liquid Separation Design Enhances Circulation Stability

160°C mould temperature controllers for applications falling between standard and high-temperature control requirements

For manufacturers needing a maximum temperature above the capacity of standard 120°C water-based mould temperature controllers, the 160°C high-temperature mould temperature controller is the ideal choice.

The selection criteria are very straightforward:

  1. If standard mould temperature control meets your requirements, select a 120°C model.
  2. Where engineering plastics processing requires a higher and more stable water temperature range, select the 160°C model.
  3. Where the 160°C model cannot provide sufficient operating margin, select the 180°C model.
  4. If the required temperature exceeds the practical operating range of a high-temperature water temperature control unit, use an oil temperature control unit instead.

 

 

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