Hasco’s Cooling Tornado New standard ensures major gains in mould cooling efficiency

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When 150 mouldmakers in a 320-strong manufacturing group adopt one cooling concept across the toolroom, it is worth paying attention. Bekto’s complete conversion to Hasco’s Cooling Tornado suggests a new standard may be emerging in mouldmaking.

Bosnian mould maker Bekto Specijalna Izrada has fully converted its toolroom to Hasco’s Cooling Tornado core cooling system, citing major gains in cycle time reduction, energy efficiency and maintenance performance.

“The Cooling Tornado is a revolution for the entire industry,” says Redžo Bekto, full of enthusiasm about the Hasco innovation, which is marketed under article number Z9665/… The founder and Managing Director of Bekto Specijalna Izrada (BSI) appreciates the numerous advantages of the product in terms of energy savings, shorter cycle times, and significantly longer maintenance intervals. Overall, this leads to a considerable reduction in costs.

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When Asim Spahović, Area Sales Manager for South East Europe at Hasco, presented the new Cooling Tornado Z9665/… to Bekto Specijalna Izrada d.o.o. (BSI) in Goražde, Redžo Bekto was initially sceptical. “The following day, I installed the two samples from Hasco into a mould and observed the process over a period of several days,” said Redžo Bekto, recalling his first experiences with the Cooling Tornado. It quickly became clear to him that the temperature difference on the mould surface, compared with the conventional cooling method, was significantly reduced. “This led to a situation in which the cycle times when using this product fell from 57 seconds to 23 seconds.” The initial scepticism thus quickly gave way to genuine enthusiasm.

The Cooling Tornado Z9665/… generates a turbulent flow in the cooling bores — alternatively, the product can be used in runners for core cooling. By creating a turbulent flow, the effectiveness of the cooling is increased by up to 20 percent, ensuring uniform temperature distribution. Hotspots are avoided, and the far more efficient cooling leads to significantly shorter cycle times. This results in energy savings of between 20 percent and 40 percent, which is another decisive advantage. “The plan is that, by the end of the year, measurements will be carried out on the moulds to obtain an exact figure for the energy savings,” said Asim Spahović.

At present, 320 employees work at BSI in the east of Bosnia and Herzegovina — of whom 150 are employed in mouldmaking alone. Around 600 injection moulding and die casting moulds are produced each year. Including mould corrections, this impressive figure rises to 1,670. Furthermore, the company produces plastic articles for various industries — including automotive, household goods, electronics, sporting goods and fittings — on 60 injection moulding machines with clamping forces of 50–850 t. “BSI has aligned its portfolio with international demand,” explains Erwin Bekto — grandson of the company founder, and soon to follow in his grandfather’s footsteps.

Fewer deposits in the cooling channel: Longer maintenance cycles

After two weeks of testing, says Redžo Bekto, the moulds were dismantled and the inner diameter was measured. “The cooling channels looked almost new,” he reports, moving on to another advantage: on the inner surfaces of the cooling channels, there are virtually no deposits at all. “This, too, is an effect achieved by the turbulence of the medium,” adds Asim Spahović. Through the use of the Cooling Tornado, maintenance cycles are extended from three to an estimated twelve months. Here too, BSI aims in future to obtain even more accurate data, which would be important for future maintenance schedules. When projected across a full production year — and given the number of active moulding tools — there are already clear signs of significant cost savings in the maintenance process.

Retrofitting the moulds can be carried out very quickly, and assembly is easy. Hasco offers the Cooling Tornado in diameters of 8–15 mm and lengths of 250 and 500 mm. Thanks to its ability to be shortened precisely, the product can be individually adjusted to the length of the runner or cooling channel. Redžo Bekto reports that customer enquiries are reaching him daily, asking where the product can be purchased. Moreover, feedback regarding the improved cooling performance is also being incorporated into the obligatory mould optimisations. “So far, not a single customer has declined our proposal,” says Redžo Bekto with a smile. Accordingly, BSI has already ordered around 1,000 units in various lengths and diameters in order to be able to react quickly in its customers' interests.

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“The innovation of recent years in mouldmaking”

Redžo Bekto has been working successfully with Hasco for more than 40 years as a supplier of standard mould units. “In fact, the very first order was a project of enormous scale. I can truly say that the cooperation over the decades has developed well and has been worthwhile for both sides.”

“For me, this new development from Hasco is the innovation in mouldmaking in recent years,” says the technical enthusiast, full of conviction. “The performance these Hasco products deliver is overwhelming, especially in relation to the low purchase price.” As far as he is concerned, there is no doubt that the Cooling Tornado — which was voted Product of the Year by readers of the German Kunststoff-Magazin and won the Ringier Technology Innovation Award in China — should become the standard for all moulding tools. He recommends that every mouldmaker should at least test this product once — because any expert would recognise the advantages straight away.

With over 50 years of experience in cooling technology, Hasco is the leading specialist partner in this field. Back in 1971, the first nipple was developed with the corresponding quick-action coupling and patented. Continuous new and further developments have enabled the expansion of one of the most comprehensive system programmes for cooling technology in mouldmaking. The development of the Cooling Tornado marks another milestone in the company’s 100+ year history.

www.Hasco.com

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