In good shape

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HASCO Hasenclever GmbH + Co KG

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SKZ - KFE gGmbH

Low maintenance through ‘extra coating’

Additional impairments caused by the loosened limescale sedimentation of other machines as well as algal formation can also disrupt the cooling process, explained Mr Oberlies. You technically transfer the problem if more than one machine is connected to the cooling unit. However, this risk can be reduced by cleaning the tools chemically from time to time, the specialist explained. There are specific devices for this process that are connected to the machine’s cooling system. A cleaning solution, heated to approximately 60 °C, breaks down the deposits. The thickness of the limescale layer dictates the length of the cleaning process. The cleaning agent is neutralised once the process is completed. It is recommended to close the cooling channels afterwards and to conserve these before storing the machine. Cleaning success can also be determined by the measurement of the reference volume taken from the construction CAD data or by comparing the actual to the theoretical flow rate.

Henkel

Proper mould maintenance takes more than just the right technology

There are other ways to profit if you lack the time or motivation to look after your tools, or do not want to invest too much in maintenance and repair. Udo Daniels from Novoplan came to talk about this topic at the SKZ seminar. His lecture covered the opportunity of applying a particular coating to injection moulding tools, which makes them low maintenance. Mr Daniels elaborated on the so-called “PlanoTek” layering technique that coats all metal parts of the machine, including sintered and hardened components like copper but also other non-ferrous metals.

The Nickel-based “PlanoTek” layer comes with a variety of advantages, said Mr Daniels. For example, there is the lack of edge development and the benefit of applying the coating at a relatively low 90 °C temperature. The thickness of the coat can also be defined and varied, the erosion and etching structures are preserved, and plane parallel coatings can also cover ribs and boreholes. Furthermore, coating combinations can be created, which also make a re-coating or de-coating possible.

Mr Daniels explained that the coating could also be reworked by grinding, degrading, or polishing. Nearly every component of the injection moulding tool can be processed with the “PlanoTek” coating. The ejector system, for example, is treated with a sliding coating, which prevents fretting of moving parts, said Mr Daniels. Tests showed that an approximately 5-µm thick coating layer was still able to perform after 3.5 million cycles. Mr Daniels mentioned that 10-µm thick “PlanoTek” coating variants can prevent deposits in hot runners or cooling channels. They also serve as corrosion protection, prevent wear and tear, and deposits. Injection moulding tool plates can also be coated; this protects them against perspiration (from hands), water, and shields against aggressive polymer melts. Thus, storage without conservation is possible. Fretting corrosion should also be eliminated.

Wear protection is an excellent option for components that are ‘softer’ like copper or aluminium to ensure functionality, stated Mr Daniels. The thermal conductivity of the construction materials is not affected by this. There are “PlanoTek” coatings, which serve as a demoulding aid or prevent forming of plaque, to upgrade the cavity. A coating of 2 µm ensures that parts can be removed more quickly and easily.

Gallery

Nevertheless, all the technical advantages are not substituted by dedicated staff who work with ‘open eyes’ and adhere strictly to all action plans, by paying attention to duty hierarchy, therefore ensuring that operating materials are always ready for use. This approach allows companies to stay competitive and convinces the clients of their suppliers' abilities.

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