This is a question faced by companies looking for solutions to address the issue of declining cooling efficiency in tools due to gradual buildup of scale and rust deposits. The answer is not straightforward and could be summarized as „it depends.” To properly select a device that will work well in your facility, several key factors should be considered. Below, we briefly discuss each of them:
Price vs. Efficiency
Price is always a key factor in purchasing decisions, especially when multiple departments are involved in the decision-making process. It is worth looking closer at what a given price includes, as it may turn out that the capabilities and performance of a seemingly more expensive solution result in a faster return on investment than a cheaper option. This can be influenced by factors such as the number of cleaning sections or the cleaning technology itself. For example, the CA6 device, which has six independent cleaning sections, allows for an average of 240 molds to be cleaned per year, assuming that each channel is connected to the device separately (without circuit bridging). This provides six times the performance of single-circuit devices that are popular in the market. Bridging circuits for cleaning is always discouraged due to increased pressure drops, which negatively affect the pump’s dynamics and increase the risk of channel blockages. A larger number of cleaning sections gives greater flexibility, especially when each section is equipped with a dedicated set of pumps. Such a solution, of course, costs more than a system built on a single pump. The final decision is up to the buyer, but it is important that this decision is made consciously, understanding the physics and dependencies involved.
Automation of the Process and Personnel Involvement
Another factor to consider when choosing a device is the level of automation of the entire process. There are simple and inexpensive manual devices on the market that require the operator to manually set individual operations. As labor costs rise, companies are increasingly leaning toward solutions that minimize human involvement. In addition to manual and semi-automatic devices, our portfolio includes advanced units that practically reduce operator tasks to connecting the mold, selecting it from the database, and pressing the START button. Advanced algorithms carry out the entire process, from mold blowout, leak and flow tests, measurements, cleaning, rinsing, and system drying. This approach also minimizes the risk of operator errors.
Collecting data on Cooling Efficiency and Mold Condition
When choosing a device, it’s worth asking whether you’re looking for a unit that only allows cleaning or one that offers additional functions, such as flow rate measurements, leakage & blockage tests, or channel rinsing. You may even be looking for a solution that enables the collection of cooling efficiency data over the entire life of a mold, with the ability to generate reports and program the machine to reference the information in the database during cleaning sessions. Collecting information on cooling efficiency changes over time is one of the biggest added values a device can bring to a company. This allows the maintenance department to implement a preventive cleaning policy, saving a lot of time and often stress. Combining a database with intelligent machine modes, where the device can be programmed to clean until reference flow rates or stable flow rates are achieved, further saves time and eliminates the risk of damaging the tool due to overly long cleaning sessions. After all, how is an operator supposed to know how long the cleaning should take?
Safety of Operation
Often overlooked in the early stages of the purchasing process, this aspect is actually one of the most important. It’s not uncommon for molds that require cleaning to be worth hundreds of thousands of euros. Therefore, you need to be confident that in the event of an unexpected situation, such as a leak, the machine can autonomously and quickly decide to stop the process. A common solution in cheaper devices is the use of floaters, which are supposed to „guarantee” maintaining the correct amount of liquid in the tank. However, they do not protect against leaks because their response time is too slow. Therefore, it’s worth looking for solutions based on ultrasonic sensors, which, with surgical precision, control the liquid level in the tank and can respond quickly to leaks, stopping the process. This is just one example of the safety features used in the CS and CA series devices.
Process Effectiveness
All the factors mentioned above may become secondary if the cleaning process itself is ineffective. Conventional cleaning methods rely on pumping chemically active solutions through channels using either rotary or diaphragm pumps. The flow dynamics through the channel are so low that the process entirely depends on the effectiveness and aggressiveness of the selected cleaning agent, aimed at dissolving deposits. This cleaning method, combined with a lack of process automation and effectiveness monitoring, increases the risk of tool damage, as cleaning time depends solely on the operator’s assumptions. An alternative solution is cavitation cleaning, where the cleaning medium only softens the deposits, and the actual cleaning and removal of scale take place mechanically. A sudden pressure drop creates millions of vacuum bubbles, which collapse and generate shock waves, breaking up the deposit layer on the channel surface. Thanks to the incomparably higher dynamics of the process, hybrid cavitation cleaning allows for a significant reduction in the total cleaning time, which is another argument in favor of choosing this cleaning technology.
Internal Company Analysis
Finally, it is important to note that the machine that will best suit a given facility largely depends on:
- Nature of production – Whether the production is for the automotive, medical, or optical industries, where both molds and reporting requirements are very stringent.
- Number and size of molds – For larger quantities of tools and channels, devices with a greater number of cleaning sections are recommended. Choosing such a device will have a direct impact on process efficiency without the need to serially connect channels.
By carefully considering these factors, you can select the right cooling channel cleaning device that not only improves your cooling efficiency but also optimizes your overall production process.