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Why is the preheating function of the mould temperature controller so important?

2025/05/14 By Topstar

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When changing moulds, operators must wait for the new mould to preheat to operating temperature and the old mould to cool completely before removing it. This waiting time is often more than 30-60 minutes, leading to lost production time. A mould temperature controller with preheating function can automatically start heating one hour before the expected mould change, thus bridging this gap and ensuring that the next mould is at the optimal temperature when installed. As a result, mould changes are faster and downtime is reduced, allowing manufacturers to meet the needs of high-mix, high-volume production in areas such as automotive or consumer electronics packaging. And by integrating the preheating function into the workflow of the mould temperature controller, production efficiency will be significantly improved.

Shorten mould change downtime through forced cooling of the mould temperature controller.

The mould change process requires sufficient cooling of the hot mould to ensure safe operation. The mould temperature controller with forced cooling function solves the problem of long cooling time by continuously opening the cooling solenoid valve after production to allow the maximum coolant flow to flow through the mould channel. In a mould temperature control system, forced cooling can reduce the mould temperature from 200°C to below 50°C in about 10 minutes. The timed cooling function of the mould temperature controller precisely manages this rapid cooling, minimizing non-productive intervals. The timed on-off feature further enhances this benefit by enabling a seamless transition to the preheating phase. Combining rapid forced cooling with intelligent preheat scheduling eliminates traditional temperature cycle delays, allowing for faster mould changes.

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Timed On/Off Functionality and Preheat Scheduling for Mould Temperature Controller

The heart of the advanced preheating capabilities in Topstar’s mould temperature controllers lies in their programmable timers. Users enter the estimated mould change time into the controller interface, and the system automatically powers the heater cartridges at predetermined intervals to reach the set temperature when the mould arrives. Mould temperature controllers with timed on-off functionality replace manual intervention and guesswork by automatically achieving optimal temperature conditions without requiring operator supervision. Combined with an intelligent PID control loop, the mould temperature controller balances heater output and coolant flow during preheating to avoid overshoot and maintain uniform mould temperature. This precise timing reduces energy waste by heating when needed and ensures that production resumes immediately after mould installation.

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Improved Productivity and Cycle Time

Implementing the preheating feature in advance can bring significant productivity improvements to any injection moulding plant. By shortening the mould change window by approximately 10%, an 8-hour shift can accommodate additional mould changes, equating to tens of thousands of additional parts per year in high-speed packaging applications. Mould temperature controllers equipped with preheat and forced cooling can significantly reduce the average downtime per mould change from 45 minutes to less than 20 minutes, freeing up machine production cycles. For industries that require frequent mould changes, such as medical device or consumer electronics manufacturers, this feature ensures maximum mould temperature controller utilisation, reduces labor costs for manual preheat monitoring, and shortens lead times.

Improve part quality through thermal consistency

In addition to increasing production, the mould temperature controller’s preheat function directly impacts part quality. Stable mould temperatures minimise thermal gradients that cause weld lines, sink marks, or dimensional deformation. The mould temperature controller ensures that the molten polymer fills the cavity under uniform conditions from the first shot by preheating the mould to the precise process temperature before production begins. This uniformity results in a better surface finish and reduced scrap rates. Topstar’s mould temperature controller with preheating schedule provides this consistency, allowing manufacturers to adhere to strict quality standards while maintaining fast mould changes.

Driving innovation in automotive parts

Remote operation and intelligent integration

Topstar integrates its mould temperature controller with injection moulding machines through a unified communication language under its self-developed control system, and also connects it with MES. Engineers can schedule preheating cycles, adjust setpoints, and monitor real-time mould temperatures of multiple machines from a central control room or even a mobile device. This mould temperature controller connection function helps predictive scheduling, ensuring that moulds receive accurate preheating commands when needed, or during non-working hours or shift changes. At the same time, automatic alarms notify operators of temperature deviations or maintenance needs, reducing unplanned downtime. Manufacturers can optimise their thermal management processes and overall production workflows by embedding advanced preheating functions into a broader industrial intelligence framework.

Maximise production efficiency through preheating.

Especially in multi-variety, high-volume production industries, the preheating function of mould temperature controllers can greatly improve production efficiency. Combined with forced cooling, precisely timed power control and networked scheduling, non-productive downtime is significantly reduced, mould change efficiency is increased by up to 10%, and ensuring part quality through stable thermal conditions.

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