Now we discuss the pros and cons of sending a flashed manifold out for repair versus performing this task in-house. This article will begin to deal with the disassembly, troubleshooting, cleaning and reassembling of a typical, and flashed 16-cavity valve gate manifold.
Obviously there are many different makes of hot runner manifolds currently being used in the making of plastic parts today. Relevant (and most critical) design differences that will affect a manifold’s potential to leak concerns how the nozzles, sprue and any cross-overs (or bridges) are connected to the manifolds. These components are either bolted to, threaded into or rely on a compression stack, and sometimes a combination of all three. Each type has its trade-offs concerning required maintenance of the system and the overall ease of installing replacement parts, such as thermocouples, nozzles, nozzle tips and heaters.
Regardless of flowery forecasts made by manifold sales folks, the ease at which a manifold system can be maintained will not be apparent until the system has some hours on it (a million cycles would be nice), giving internal components, pockets and tooling clearances time to collect vent residue (greasy film or powders) and weepage (gooey, degraded plastic).
Also impacting manifold condition are molds stressed through weekend shut-downs and hurried Monday morning start-ups along with touchy gate/valve pin tip configurations that promote out-of-spec gate vestiges—forcing processors to fiddle with the parameters.
Some systems require a complete teardown just to replace a nozzle heater or thermocouple. On others, if specific components are disturbed or removed they too must be completely disassembled and cleaned before reassembly to ensure proper component stack dimensions.
The level of disassembly/reassembly (labor hours and skill level) required over time to replace basic components along with the usage (cost) of the components will determine the true ease of maintenance with the system.
But obviously, any manifold that encapsulates easily (easily meaning that if a strict start-up procedure is not followed to the letter, the system has the capability to blow at multiple locations) will not be a popular choice among those of us who have to fix or run them.
For the sake of fairness and consistency, we will examine areas of concern regardless of the manifold make and model.
In manifold maintenance, the same five basic principles that apply to a mold also apply to an encapsulated manifold. The only difference is that troubleshooting the source of the leak could be ongoing throughout the repair process as plastic is removed and more tooling is exposed—allowing better visual inspection of seal areas and components, right up through assembly of the cleaned components.
Here is an overview of the five basic steps that will occur on an encapsulated system:
1. Disassemble
Remove the valve pins and clamp plate, and disassemble mold to gain visual access to the back of manifold.
Pay attention to tooling clues that can point to the leak source (bent, broken or galled valve pins and the amount and type of residue around the pin).
Remove enough plastic as to facilitate separating the manifold and electrical box from the plate, so that you can clean these components separately.
2. Clean
Clean clamp plate, manifold plate channels, counter-bores and valve pins (ultrasonic).
Clean nozzles, heater and thermocouple wires and manifold (by hand).
3. Troubleshoot
Inspect seal areas of components for obvious cracks and plates for hobbing and bolts for looseness.
4. Assemble
Reassemble to stage one.
Electrical check.
Final reassembly to stage two.
5. Final Check
Electrical check ramping heaters up to processing temp with water flowing through appropriate channels.
Let’s begin with the mold in the press. The first noticeable sign of a flashed manifold is usually when smoke is seen rising from the top of the stationary side, or plastic oozing from places it shouldn’t … then the panic and finger pointing ensues.
But there are other, more subtle clues that might point to a manifold leak, such as molds that produce periodic incomplete shots, shorted out heaters and thermocouples in a particular quadrant.
Paying attention to these signs can alert a processor to a possible manifold malfunction and allow them to shut a mold down before the manifold is totally encapsulated.
Disadvantages of Hot Runner System
While the hot runner system offers a wide range of significant advantages over the cold runner systems, users of molds also need to understand the disadvantages of hot runner systems. It will help users to decide effectively before choosing the right runner system for their projects. To sum up, the disadvantages of hot runner systems include:
The complexity of operation & Maintenance / High requirement for equipment / Increased cost / Thermal contraction and expansion / Degradation of heat-sensitive resin
1 The complexity of operation & maintenance
The hot runner mode of operation and maintenance is complicated. As a result of its complexity, it may easily damage the hot runner part if proper precaution is not taken. This may lead to a big economic loss for the company. Likewise, for new hot runner users, it may take a while to gain the experience for proper maintenance and operation.
2 High requirement for equipment
The requirements for the use of hot runner is on the high side. The hot runner mold requires precision processing machinery in both cooperation and integration. If the requirements are not supplied at its best, the components may develop serious problems during production. For example, whenever the plastic seal is faulty, then the plastic melt overflows and damages the hot runner components. Another example – when the nozzle and the gate are not properly placed, it will affect the product quality negatively.
3 Increased cost
In terms of cost, hot runner components are expensive. This in turn leads to a significant increase in the general cost of purchasing the hot runner mold. Also, if your company has a low production rate, then the use of the hot runner may be unnecessary or not economical. In developing countries, the use of hot runner systems is widely affected due to its expensive nature.
4 Thermal contraction and expansion
There are different hot runner systems out there with various designs. For some of these hot runners, they exhibit thermal contraction and expansion. This is attributed to the constant heat produced during processing. Also, heat radiation produced during the period of production may be difficult to control.
5 Degradation of heat-sensitive resin
The use of a hot runner system for heat-sensitive resins may require extra care and great expertise. If proper care is not taken, users may have to deal with degradation. The degradation may be in the form of sight color change or as complex as the cross-linking of the molecular chain.
Repair technicians must be properly trained in hot runner characteristics so that companies are not experiencing unnecessarily long and expensive downtime hours while waiting to get a mold return from an outside vendor. repairing and maintaining a typical hot runner system takes maintenance skills to the next level. successful hot runner repair requires a higher level of understanding, concerning how they function and their critical areas that need to be monitored. safe, precise, and reliable repairs can only be accomplished in a methodical approach that utilizes accurate documentation and a thorough knowledge base that guides technicians through specific procedures during maintenance and repair work. tooling in a typical hot runner system must be handled with great care while cleaning inspecting and reassembling. specific practices and techniques must be used to prevent potential flooding or encapsulation disasters that can plague all hot runner systems. also discussed are various processing techniques and resins that can have a huge effect on the performance, condition, and maintenance practices of a hot runner system. the cleaning procedure of manifold cleaning, refurbishment, electrical on hot runner systems is crucial.
There are two choices for cleaning up the system: the first choice is to send it to a qualified service center where the system will be placed in an oven at high temperatures to burn off the excess plastic. the advantage of this method is a fast turnaround with new thermocouples and heaters. the disadvantage is cost. new thermocouples and heaters are expensive. time is also a factor, it may take about a week to have the mold returned or longer if 48 heaters cannot be quickly found. the second choice is to clean it in-house. this option can save thousands of dollars, including a 50% to 75% savings just in thermocouples and heaters. a determination also can be made from where the leak came from. knowledge can be gained on how to prevent future leaks and the overall operation of the system. house repairs properly executed will always save time and money. there are disadvantages to an in-house repair it can take 40 man-hours or more to completely clean and rewire the system on a typical 48 cavity mold, even longer if you don’t have the proper equipment. cleaning and repairing an encapsulated system also requires a higher skill level to troubleshoot, clean, and reassemble without further damage. failing to do this correctly can cause the system to flood again. due to an unrelated issue that caused the first flooding. many hot runner manifold problems can be traced back to a lack of knowledge concerning hot runner assembly mistakes, poor work habits, improper tools use during the clean and repair of the manifold, and critical components.
Here are some methods and tools that will make it possible to separate the wires properly and safely and allowing the heaters and thermocouples to be removed. this must be done first to remove the nozzles from the plate for cleaning and inspection. For example, a 48 cavity valve gate system that was completely flooded from the front or nozzle tip side of the hot half of the mold. it appears that there is a major leak between the nozzle seal and the cavity block, allowing the plastic to flow into the wire channels, then back into the manifold. unfortunately, this completely encased the wires in plastic, or in this case polypropylene. several different colors could be seen, so the leak was not detected immediately. since the mold is going to need a complete teardown, the electric control box, manifolds, bridge have been removed. all wires have been numbered and disconnected so they can be thread through the wire channels in the plate one at a time. on this mold, the thermocouple wires run along the entire length of the nozzle, making removal from the front impossible. this will necessitate removing the nozzle from the back just to get to the thermocouple. on better design systems, thermocouples are easily removed from the front of the mold instead of requiring a complete manifold removal just to change out a defective one. make sure the necessary safety equipment is present. this includes a full face mask, heat-resistant gloves, and a shop coat.
a vacuum system to draw off as much of the smoke as possible as desirable as is plenty of light, tilting the mold back at about a 20-degree angle is helpful to get it into a more comfortable working position, resulting in better control of melting and separating the wires. the objective is to see exactly where the wires are routed through the channel and to which heater, so the wrong wire will not be pulled, which could break it. even though the control box has been disconnected and removed, the heaters can still be warmed up to remove the plastic that surrounds them. using a special tool and a direct connection to a 110-volt plug. the individual band heaters can be heated to remove the plastic that surroun
The Hot Runner is a system for molding which saving the materials usage, the materials runner extensive a longer way getting closer to the mold cavity. The system working without wasting plastic. It saved a lot especially for some expensive materials. It is popular although the cost is higher than current mold design during large q’ty production.
The hot runner system is divided into a fully hot runner and a semi hot runner. Fully runner design is complex, but the effect is good and maintenance costs are very low. Semi-hot runner structure is simple, stable and easy to use, low failure rate, because the structure is simple ,therefore low maintenance costs, the stability of the production have a greater guarantee. Hot runner classification: open (for semi-hot runner), needle valve type (for fully runner).
Our new Hot Runner Manifold Cleaning System is the fastest, most cost saving and environmentally friendly method of removing practically all organic contaminants such as plastic, rubber or paint from steel parts. we have taken mold maintenance to a new level with the addition of our Mold Manifold and Hot Runner Cleaning System. With this operation, parts are loaded into a tank where fluidized hot sand at a temperature of 800 to 850 degrees Fahrenheit, scrubs, vaporizes, and burns off all left over organic material without damaging or warping the work pieces. The basket of cleaned parts is then hoisted out of the tank and set to cool. Now we are truly able to inspect and evaluate your jobs specific situation then dissect and address the issues necessary.
Repair technicians must be properly trained in hot runner characteristics so that companies are not experiencing unnecessarily long and expensive downtime hours while waiting to get a mold return from an outside vendor. repairing and maintaining a typical hot runner system takes maintenance skills to the next level. successful hot runner repair requires a higher level of understanding, concerning how they function and their critical areas that need to be monitored. safe, precise, and reliable repairs can only be accomplished in a methodical approach that utilizes accurate documentation and a thorough knowledge base that guides technicians through specific procedures during maintenance and repair work. tooling in a typical hot runner system must be handled with great care while cleaning inspecting and reassembling. specific practices and techniques must be used to prevent potential flooding or encapsulation disasters that can plague all hot runner systems. also discussed are various processing techniques and resins that can have a huge effect on the performance, condition, and maintenance practices of a hot runner system. the cleaning procedure of manifold cleaning, refurbishment, electrical on hot runner systems is crucial.
When using an injection mould tool with a Hot Runner System it is sometimes necessary to clean the system due to misuse.Typical examples of situations that result in the manifold requiring cleaning are as follows:
Manifolds Left With Power On For Extended PeriodsMany older moulding machines will not power down the heaters when the machine is shut-off, so manifolds are left to overheat. This will result in two things:
1. The overheated plastic is significantly reduced in viscosity causing the resin (weepage) to migrate into tooling clearances.
2. The tooling overheats, causing the manifold to over-expand and hob sealing surfaces, reducing the ability to seal when the manifold temperature is brought back down into range.If the plastic resin that is being processed is sensitive to heat, an engineering grade or a filled material then serious overheating can result in the material crystallising inside the melt channels of the Hot Runner System and is unable to be re-melted.
Process Habits
Failing to reduce shot size when blocking cavities, not using back pressure when filling empty manifolds, running temps to high, reversing valve pin sequence and forgetting to turn on the cooling are just a few of several processing conditions that contribute to leaking systems.
Lack of Preventative Maintenance
Worn valve pins and bushings seem to be a major contributor, particularly where manifolds are long overdue for thorough maintenance. Also lethal are hobbed manifolds, spacers and other tooling where combined dimensions are under the recommended cold stack height. This also includes stressed/stretched bolts.
Cleaning Processes
There are many processes available to assist you with thorough cleaning of a manifold. Depending on the complexity of your manifold it is often impossible to properly clean the channels inside a manifold simply by removing plugs and removing the plastic.
There are two choices for cleaning up the system: the first choice is to send it to a qualified service center where the system will be placed in an oven at high temperatures to burn off the excess plastic. the advantage of this method is a fast turnaround with new thermocouples and heaters. the disadvantage is cost. new thermocouples and heaters are expensive. time is also a factor, the second choice is to clean it in-house. this option can save thousands of dollars, including a 50% to 75% savings just in thermocouples and heaters. a determination also can be made from where the leak came from. knowledge can be gained on how to prevent future leaks and the overall operation of the system. house repairs properly executed will always save time and money. cleaning and repairing an encapsulated system also requires a higher skill level to troubleshoot, clean, and reassemble without further damage. failing to do this correctly can cause the system to flood again. due to an unrelated issue that caused the first flooding. many hot runner manifold problems can be traced back to a lack of knowledge concerning hot runner assembly mistakes, poor work habits, improper tools use during the clean and repair of the manifold, and critical components.
1) Open gate
1 cleanup barrel by plastic material with demand color.
2 heat each heating zone with the temperature by 15-20 ℃ over normal production temperature.
3 shot 10-15 times according to normal procedure.
4 move back the the injection unit (barrel),turn off the hot runner system.
5 cool down the hot runner system, which method leads to the shrinkage of hot plastic material in the runner channel due to the reduced temperature , and then separated from the channel so the old and new materials could be mixed.
6 turn on the hot runner system again and wait until the temperature rise to production demand.
7 move back barrel.
8 increase the injection speed and repeat injection molding procedure until the color of the product can be accepted.
9 gradually restore the process of setting , restore injection speed and temperature to original production process demand.
2) Valve gate
1 the hot-runner system has processed plastic material with a certain color.
2 cleanup barrel by plastic material with demand color .
3 heat each heating zone with the temperature by 15-20 ℃ over normal production Temperature .
4 shot 10-15 times according to normal procedure to clean the barrel (Note:unless hot runner reached the plastic processing temperature ,valve needle need to keep its position otherwise the valve needle and gates could be damaged when clean the barrel.)
5 move back the the injection unit (barrel),turn off the hot runner system.
6 cool down the hot runner system, which method leads to the shrinkage of hot plastic material in the runner channel due to reduced temperature , and then separated from the channel so the old and new materials could be mixed.
7 turn on the hot runner system again and wait until the temperature rise to production demand.
8 move back barrel.
9 increase the injection speed and repeat injection molding procedure until the color of the product can be accepted
10 gradually restore the process of setting , restore injection speed and temperature to original production process demand.
3) Dismantle and Clean the residual mixed color material inside hot runner . Check the injection molding machine nozzle and hot runner gate for the mixed color residual material and repeat the injection to clean that material.
There are many processes available to assist you with thorough cleaning of a set of hot runner system. Depending on the complexity of your manifold and hot runners. it is often impossible to properly clean the channels inside a manifold simply by removing plugs and removing the plastic.
Elaborate tools are used in injection molding which require regular cleaning. Screw tips, injection nozzles, static mixers and especially hot-runner systems require extremely reliable polymer removal. I am sure to have such thermal cleaning technologies guarantee such removal. Even sprayed over hot-runner distributors with complicated geometries and glass fiber contents can be cleaned gently and without residues of polymer and carbon remnants as well as inorganic contaminations.
Today’s use of hot-runner technology allows the injection molding of very complex and large components. However, the sometimes very long internal flow channels make manual cleaning impossible; the use of rinsing chemicals usually produces only inadequate results. Even for sprayed over hot-runners / hot-runner nozzles thermal cleaning is the only solution.
we have taken mold maintenance to a new level with the addition of our Mold Manifold and Hot Runner Cleaning System. With this operation, parts are loaded into a tank where fluidized hot sand at a temperature of 800 to 850 degrees Fahrenheit, scrubs, vaporizes, and burns off all left over organic material without damaging or warping the work pieces. The basket of cleaned parts is then hoisted out of the tank and set to cool. Now we are truly able to inspect and evaluate your jobs specific situation then dissect and address the issues necessary. any question, please contact
I once attended a seminar where the guest speaker was a hot-runner specialist who thanked us in the audience for our continued support of his children’s college fund through our steady tendency to encapsulate manifold wiring and other delicate components with flash. When asked reasons for these flashing follies, he cited these causes in order of frequency:
1) Manifolds left on over weekends. Many older presses will not power down the heaters when the press is shut off, so manifolds are left to cook. This accomplishes two things: The overheated plastic de grades and drops significantly in viscosity, causing resin weepage into tooling clearances. Second, the tooling overheats, causing it to expand and hob the sealing surfaces, reducing the manifold’s ability to seal itself when the temperature is brought back down into proper range.
2) Cold starts. His college fund loves impatient molders who don’t allow manifolds adequate “soak” time of 20 to 40 min to allow the steel to fully expand and create the necessary sealing pressure between components.
3) Bad processing habits. Failing to reduce shot size after blocking cavities, not using backpressure when filling empty manifolds, running temperatures too high, reversing valve-pin sequence, and forgetting to turn on the cooling water are just a few deadly sins that contribute to leaking systems.
4) Lack of preventive maintenance. Worn valve pins and bushings are common in manifolds that are overdue for a thorough going over.
5) Also lethal are hobbed manifolds, spacers, and other tooling whose combined di men sions are under the recommended cold stack height. Other culprits are stressed or stretched bolts and fatigued compression-seal washers.
6) Short cuts. Too often, in-house manifold cleanings are attempted by personnel who, for the sake of speed and dollars (or due to inexperience), try short cuts like partial disassembly and cleaning, or they fail to assemble the manifold correctly. It takes only a small mistake, such as a bolt that is not properly torqued or a probe skirt not fully seated, to create a clearance that allows melt to leak.
7) Cracked tooling. Manifolds, probes, sprues, and crossover bars/ bridges can develop small fractures that turn into major cracks under injection pressure.
8) Bad design. When shopping for a hot-runner system, it would be great to inspect one that has run a few million cycles—but you don’t see these at trade shows. Too bad.
Follow these step-by-step instructions when using an purging compound mechanical grade to clean hot runner systems with mold plates open:
1) After the screw and barrel have been cleaned thoroughly using the purging compound, set the nozzle into the mold.
2) Open the mold plates.
3) Set up a safety-approved surface for collecting the purgings.
4) Verify that the mold safety door is closed.
5) Add enough purging compound into the hopper to fill the barrel approximately ½ full.
6) Extrude the purging compound through the hot runner system starting at a medium velocity. Increase screw speed to the maximum safe level for maximum cleaning. Once it is flowing adequately through all of the gates, perform injection shots (air shots) with mold plates open.
7) Visually inspect purgings for color and/or carbon contamination.
If contamination remains, repeat steps 5 through 7 until the purging compound is visually free of color and/or carbon contamination and has returned to a clean appearance.
8) Purge out any remaining using the maximum safe screw speed.
9) Adjust the temperatures in the barrel and hot runners to the processing conditions for the next resin to be processed.
10) Flush the system with the next resin to be processed using the maximum safe screw speed until the next resin is visually free of the purging compound.
Resume production using normal production settings.
I have spent hundreds of hours chipping and cleaning manifolds of 16- to 48-cavity molds with various types of manifold systems. Some may flash easier than others, but none is immune to flashing caused by a hurried start-up by an impatient molder or caused by bolts left loose by a preoccupied repair tech. No particular brand of manifold cleans up more quickly or easily than any other. But every flashed system seems to attract a number of white shirts clamoring for a super-quick turnaround, with no apparent clue as to what the job entails.
Proven Methods And Best Practices:
Unfilled grades of ASACLEAN can pass through the same clearances as the resins being processed.
Filled ASACLEAN grades (EX, PX2 and NF are not usually recommended for hot runner cleaning. Consult Sun Plastech Inc. for guidance on using filled grades for purging hot runners.
External heating systems: Raise the manifold temperature to 20°C – 30°C (35°F – 55°F) for improved flow. If running heat-sensitive resins, do not exceed the maximum safe operating temperature of the material.
Internal heating systems: Consult with a Purging Process Expert for technical assistance before using ASACLEAN.
If available, apply mold release agent to reduce the potential for material sticking to the mold surface.
Preparation: The entire hot runner system temperature must be within the usage range of the ASACLEAN purging compound grade to be used.
Cleaning of hot runner systems using unfilled purging compound grades of ASACLEAN may now be performed. ASACLEAN purging compound that is run through hot runner channels combines with residual materials and removes them safely while leaving a minimal amount of ASACLEAN residue.
the optimal thermal cleaning method for any hot-runner size or geometry:
INNOVACLEAN – Fluidized bed pyrolysis for all polymers
MAXICLEAN – Pyrolysis systems for extra large components
VACUCLEAN – Gentle but efficient vacuum pyrolysis
The advantages of these systems are their excellent cleaning quality within very short cleaning periods, their suitability even for glass fiber-reinforced materials and their cleaning technology that is easy on materials and the environment.
Today’s use of hot-runner technology allows the injection molding of very complex and large components. However, the sometimes very long internal flow channels make manual cleaning impossible; the use of rinsing chemicals usually produces only inadequate results. Even for sprayed over hot-runners / hot-runner nozzles thermal cleaning is the only solution.
I have spent hundreds of hours chipping and cleaning manifolds of 16- to 48-cavity molds with various types of manifold systems. Some may flash easier than others, but none is immune to flashing caused by a hurried start-up by an impatient molder or caused by bolts left loose by a preoccupied repair tech. No particular brand of manifold cleans up more quickly or easily than any other. But every flashed system seems to attract a number of white shirts clamoring for a super-quick turnaround, with no apparent clue as to what the job entails.
After the dirty work is done, it will test the skills of the most seasoned craftsman to perform the precise measurements necessary to determine if combined tooling tolerances (stack-out) are enough to have contributed to the leak. Measuring mold components to within 0.0001 in. while referencing non-perfect surfaces is a time-consuming task requiring calibrated instruments, a surgeon’s touch, and excellent analytical skills. It is the part of the troubleshooting process that separates a journeyman from, well, everyone else.
Too often, in-house manifold cleanings are attempted by personnel who, for the sake of speed and dollars (or due to inexperience), try short cuts like partial disassembly and cleaning, or they fail to assemble the manifold correctly. It takes only a small mistake, such as a bolt that is not properly torqued or a probe skirt not fully seated, to create a clearance that allows melt to leak.
Cracked tooling. Manifolds, probes, sprues, and crossover bars/ bridges can develop small fractures that turn into major cracks under injection pressure.
Bad design. When shopping for a hot-runner system, it would be great to inspect one that has run a few million cycles—but you don’t see these at trade shows. Too bad.
Today’s use of hot-runner technology allows the injection molding of very complex and large components. However, the sometimes very long internal flow channels make manual cleaning impossible; the use of rinsing chemicals usually produces only inadequate results. Even for sprayed over hot-runners / hot-runner nozzles thermal cleaning is the only solution.
the optimal thermal cleaning method for any hot-runner size or geometry:
INNOVACLEAN – Fluidized bed pyrolysis for all polymers
MAXICLEAN – Pyrolysis systems for extra large components
VACUCLEAN – Gentle but efficient vacuum pyrolysis
The advantages of these systems are their excellent cleaning quality within very short cleaning periods, their suitability even for glass fiber-reinforced materials and their cleaning technology that is easy on materials and the environment.
Often referred to as runnerless molding or hot-manifold systems, hot runner molds describe a set of temperature control heating-devices installed in the mold. The purpose of a hot runner injection system is to maintain a molten flow of plastics or rubber from the injection molding machine nozzle to the gate in a plastic injection mold — keeping the runner above the melting point of the plastic.
Hot runner molding systems consist of two plates heated by a manifold system inside one-half of the mold that sends the melted material to nozzles, which feed the part cavities. The system consists of two parts: the hot manifold and the drops. The manifold moves the rubber on a single plane and parallel to the parting line to a location above the cavity. Positioned perpendicular to the manifold, the drops move the rubber from the manifold to the component.
Hot runner systems have hit their stride as the desire to reduce scrap and improve efficiency and productivity has caused mold buyers to shell out the added dollars for the technology. Husky Injection Molding Systems is one of the largest manufacturers of hot runners and temperature controls in the world, so it has a vested interest in seeing that its customers receive the benefits of these systems over the long term. To help with that, the company offers its hot runner maintenance and refurbishment program.
There are many processes available to assist you with thorough cleaning of a manifold. Depending on the complexity of your manifold it is often impossible to properly clean the channels inside a manifold simply by removing plugs and removing the plastic.
When hot-runner systems leak, experience and skilled technique should never be compromised for the delusion of a quick turnaround. The only thing that draws white shirts into the toolroom faster than a leaking manifold is one that leaks immediately after a rebuild
The attraction of cleaning a flash-encapsulated system in-house rather than sending it out is the expectation of faster turnaround and lower cost. An experienced technician can chip, clean, partially rewire, and reassemble a 16-cavity valve-gate manifold of average complexity (such as a cap mold) that is completely flashed in about 30 hr, providing he/she has a heat gun, ultrasonic cleaning tank, appropriate music, and lots of coffee.
Multiply these hours by your fringe labor costs and possibly add in a couple of replacement heaters or thermocouples and you can easily invest $1500 to $2000 in the job. But the big advantage is that if you have experienced techs available around the clock, then you only lose about a day and a half of production. That is roughly the time it takes to crate and ship the mold to an outside vendor and is the number-one reason why many cleanings are first attempted in-house.
Repairing and maintaining a typical hot runner system takes mold maintenance skills to the next level.
While all mold repair work should be performed methodically and carefully, successful hot runner repair requires a higher level of precision, understanding and accuracy that can only be accomplished in a systemized approach that utilizes accurate documentation of the critical elements of manifold work.
Tooling in a typical hot runner system must be handled with great care while cleaning, inspecting and reassembling.
Methodical practices must be used to prevent potential disasters that could be just a wrench slip, pinched wire or forgotten bolt away.
Adding to the challenge is various processing techniques and resins that can have a huge effect on the performance, condition and maintenance practices concerning a hot runner system.
common issues about maintaining hot runner system will be discussed and useful bench techniques will be taught that include:
Performance and maintenance characteristics of several popular brands of hot runner systems used today.
Working safely on hot manifolds.
Disassembly, cleaning and assembly techniques used at the bench.
Typical problems created through bad work habits—when to utilize extreme care.
Wiring how-to, splices, repairs, resistance checking, heater size verification, and replacement.
Some experience about cleaning out hot runners:
1) To clean out the runners, let tool cool and dismantle.
2) Remove end plug grub screws, (Note it may be necessary to heat manifold to loosen screws if they are stuck).
3) Before you can extract the end plugs you must remove the M4 grub screws which lock the end plugs in place. This is normally located on the top of the manifold, but may be at the bottom of the heater groove, in which case you will need to remove the heater as well. You will need to use a puller to extract the end plugs.
4)Then heat the manifold to the BOTTOM range of its processing temperature and using a hot wire with a hook on the end, try to hook out the melt just as the outer layer of plastic melts in the runner.Do not under any circumstances attempt to blow out hot plastic with an air gun.take extreme care not to scratch bores.
5)If this is not successful, heat the manifold to full operating temperature and allow to so ask for 20-30 minutes and use a tight fitting rod of soft material e.g. Aluminum to push out the plastic from the runners.
6)If the manifold has deviation plugs, contact supplier before attempting dismantle.
7)Carefully refit end plugs, making sure alignment of end radii is correct, apply anti seize to threads on set screws.
8)Torque to figures in manifold catalogue.
9)Refit manifold.
Cleaning of hot runner systems using unfilled purging compound grades may now be performed. purging compound that is run through hot runner channels combines with residual materials and removes them safely while leaving a minimal amount of residue.
if any one has any question about this issue,Please leave a message here. I am a super visitor to this website and I will answer your questions
I agree you at all,But this is not absolute experience, as long as your engineers have enough experience
it seems that cleaning a set of hot runner system is a very professional job, you need professional training before doing
do you want to clean a set of hot runner system? i don’t think this is a good idea, but the experience you shared in this blog is very good.
good post! thanks for sharing your experience about cleaning hot runner system
I think it is more professional to complete a set of hot runner system.
I love all the points you’ve made in this article, but in my opinion, this professional work belongs to professional engineers, happy new year!
thanks! happy new year!
although this is a good article in cleaning hot runner system, but I don’t recommend to clean hot runner system by ourself.
this kind of job is very professional, i recommend professional guys to do it.
actually cleaning a set of hot runner system is a very professional job.
I want to say this is a good article about cleaning hot runner system, but in my opinion, that kind of professional job should be completed by professional engieer
I think this is a professional technical work
your experience on this issue is worth learning, actually that job need professionals
professional job has to be done by professional guy!
professional guy should do professional job
we have many moulds with hot runner system, as for how to clean, this article really give us some suggestion
this article is very helpful for our injection molding engineers
I always think that kind of work should be done by hot runner company
but I still want to say, even you know this experience, when cleaning a set of hot runner system, you also need to get help from professional guys
I will recommend this article to our mold engineers. it is very useful
I think our mold engineers will need this article:-) thanks!
good blog! your experience on this issue can help our molding engineers
your experience is very useful, and this is a professional job
I think your experience is very useful for me, I learned something useful from this article. thanks!
professional job is for professional guys
I think this job is very professional, maybe you could do that!:-) Thanks for sharing!
your experience is very useful, but I think many molding engineers just learn it but can not clean a set of hot runner system by themselves
thank you for sharing your experience on this issue. I love your blog
this blog will benefit our injection molding engineers!
your experience on this issue is very helpful for our molding engineers
I appreciate your sharing
I want to show my thank to you for sharing this article
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