Mold Cleaning Machine

Mold Channel Cleaning Machine

DB-D2K

Issues in Circulating Water Systems & Thermal Degradation

In plastic injection molding and high-heat industrial processes, circulating cooling water undergoes continuous thermal cycling. This environment forces dissolved calcium and magnesium ions (Ca2+, Mg2+) to precipitate out of solution, forming mineral scale, hard calcium deposits, and iron oxide rust along the inner walls of internal cooling channels.

• Flow Rate Constriction: Scale accumulation reduces internal pipe diameters, exponentially increasing fluid friction and restricting flow rates.
• Thermal Interface Loss: Deposits form an insulating thermal barrier, severely degrading heat transfer efficiency between the mold body and cooling medium.
• Molding Quality Defects: Unstable and uneven thermal dissipation causes part cooling imbalances, yielding structural and cosmetic defects such as flow marks, void bubbles, warpage distortion, and sink marks.
• Structural Degradation: Corrosion beneath scale deposits leads to channel wall perforation, systemic fluid leaks, unplanned equipment downtime, and prematurely shortened tool life.

Thermal Resistance & Energy Consumption Dynamics

Accumulated scale acts as a heavy thermal insulator. According to baseline reference data from the American Institute of Refrigeration and Energy Use Monitoring Center, precise scale thickness directly correlates with compounding energy penalties:

Given that central air conditioning accounts for approximately 30% of urban commercial electricity usage and industrial compressed air/water cooling networks consume nearly 20% of total industrial power, aggressive scale mitigation is a vital requirement for corporate energy compliance and cost containment.

1. Forward Pure Water Cleaning: Flushes loose debris and prepares internal channels.
2. Forward Air Pulse Blasting: Delivers directional kinetic impact to fracture rigid mineral scale.
3. Reverse Air Pulse Blasting: Alternates impact vectors to detach stubborn, layered scale and oxide deposits from blind corners and elbows.
4. Compressed Air Purge & Blow-Dry: Completely evacuates fluid and suspended solids, drying channel walls to prevent immediate re-oxidation.

Detached particulates are carried into the unit's integrated dual filtration and settling system before controlled discharge via a dedicated sewage outlet.

Primary application fields

The technology is specifically designed for high-heat, fluid-dependent production environments across several core sector:
• Plastic Injection Molds: Multi-cavity, hot runner, and highly complex cooling networks.
• Metal Die-Casting Molds: Thermal management channels subject to high thermal shock.
• PET Preform Molds: High-precision, high-speed thin-wall bottle tooling.
• Industrial Heat Exchangers: Shell-and-tube, plate, and central refrigeration unit condensers.

Key Operational Advantages

• High Cleaning Efficiency: Removes over 95% of internal scale and rust via non-destructive physical pulse
scouring.
• Eco-Friendly Dual-Tank Architecture: Features two independent tanks—one for pure water flushing and
one for eco-friendly, food-grade descaling agents (e.g., citric acid)—eliminating harsh chemical hazards.
• Online Cleaning Capability: Connects directly to mold inlet and outlet ports while tooling remains mounted
on the press, cutting manual labor by over 90%.
• Quality Assurance: Re-establishes nominal thermal equilibrium, shortens molding cycle times, and
eliminates over 90% of part defects linked to inconsistent cooling.

System Architecture & Component Integration

Built with premium industrial-grade hardware, the DOUBLE-EASY platform is engineered for continuous duty in demanding
manufacturing environments:
• Control & Automation: Mitsubishi PLC control module coupled with a full-color human-machine interface (HMI).
• Electrical & Sensing Safety: Schneider electrical protection breakers, Keyence ultrasonic inline flow meters, and
Kitz pulse controllers.
• Pneumatics & Fluid Handling: SMC air booster systems, CNP high-efficiency water pumps, and heavy-duty SUS304
stainless steel tanks.
• Integrated Safety & Logging: Leak and pressure testing, real-time pressure monitoring, automated high/low fluid
level alarms, cycle timers, flow logging, and forward/reverse solenoid arrays.

Cleaning Thoroughness & Internal Channel Assessment

Industrial endoscope inspections verify that high-pressure physical pulse flushing completely strips persistent calcium
deposits, scale, and iron oxide layers down to bare metal.
Compared to basic compressed air purges or static chemical soaking, the bi-directional pulse system delivers over 90%
greater internal cleanliness without causing micro-abrasions or structural etching to be specialized internal channel alloys.

Intelligent Control Interface & Data Logging

The system is managed via an intuitive touchscreen PLC platform displaying real-time operational parameters:
•Water Pressure (MPa) and Air Pressure (MPa)
•Instantaneous Fluid Flow Rate (L/min)
•Inverter Pump Frequency (Hz)
•Active Phase & Remaining Cycle Duration

Custom Control Modes & Parameter Settings

The software environment includes sub-menus for precise operational tuning:
•Time Setting: Quick-select presets (1 h, 2 h, 4 h) or fully customizable run cycles spanning 30 to 480 minutes.
•Gas Seal & Leak Test Interface: Programmable differential pressure parameters, pressurization timers, and holdchecks (e.g., maintaining 0.50 MPa for 50 seconds) to verify mold seal integrity before fluid introduction.
•Flow Test Interface: Automatically benchmarks live flow rates against factory baseline parameters to verify flow recovery percentage.
•Blow Dry / Drainage Settings: Custom configuration of compressed air purge duration, pulse frequency, and purgeinterval loops.

Comparison: DOUBLE-EASY vs. Conventional Methods

Financial Benefit & Return on Investment (ROI)

Reference Model: Automotive Injection Facility operating 100 mold sets on 100T–1000T presses.
•Yield Rate Improvement: Increasing good part output from 95% to 97% yields ~€11,491/year (based on 200,000monthly units at €0.16/unit).

•Cycle Time Reduction: Cutting average cycle time from 40s to 38s generates €19,152 in added annual presscapacity.
•Labor & Chemical Savings: Reduces annual manual maintenance overhead from €23,940 to €6,650 (saving€17,290/year).
•Total Direct Return: Over €47,880 annually, achieving full machinery payback within months.

Case Study – Foxconn facility

•Initial Integrity Check: Pre-cleaning gas seal test executed at 0.8–0.9 MPa held for 20 seconds.
•Operating Profile: Pulse blasting at 0.50 MPa water pressure followed by automated air-purge drainage.
•Inspection Results: Endoscopic analysis confirmed total removal of heavy white calcium scale and iron rust,restoring original channel walls.