With the preceding basics in mind, let’s look at some cooling conditions in actual molding situations and some data taken from lab experiments.

Once you decide you need a certain flow rate, you need to know what it takes to get there. Higher flow rates can be achieved by increasing pressure or reducing flow resistance. If you are installing a new plant circulating system, it’s a good idea to pay careful attention to the pressure issue. This means using a big enough pump and large enough distribution lines throughout the plant. But when you are stuck with the water delivery system you already have, you must work on reducing resistance. Here are some suggestions.

Design mold cooling passages as large as practical to reduce resistance to flow. Next, look at the size of pipe or quick-connect fittings going to the mold. Note the change to 2.3 gal/min from 1.7 gal/min brought about just by changing from 200 series to 300 series quick-connect fittings and changing to a slightly larger drilled passage. The same effect generally follows increasing hose sizes. For example, our lab has an available water pressure of 85 psi, but it is impossible for more than about 2.5 gal/min to flow through 0.25-inch hose. In many plant situations, water pressure is much lower than 85 psi.

Water manifolds can also make a big difference. It does no good at all to have 12 0.5-inch NPT(National Pipe Taper) fittings coming off a manifold with only a 0.75-inch NPT inlet to supply all those fittings. A well-designed manifold should have a supply area roughly equal to the discharge area, or as large as practical. For example, 16 0.5-inch NPT fittings require about a 2-inch NPT supply for best performance. Also, the main supply and return fittings and hoses to the manifolds should not be smaller than the manifold inlet. Attention to these details can improve the pressure available at the mold.

If you are interested enough in all of this that you would like to learn more about your cooling conditions, you need to know what equipment is available to monitor and control flow rates, pressure, and temperature in your mold cooling circuits. A number of companies offer products to distribute cooling water and to monitor or control mold cooling variables.

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