Construction Anchors

iFLOW - Optimizing Applications Transitioning from Cold Runners to Hot Runners

A Global OEM construction materials supplier had been producing wall anchors (part weight range: 1.5g to 12g) for decades using cold runner systems. As equipment was due for replacement, the decision had been made to begin converting these cold runner systems to hot runners to achieve production efficiencies and lower costs.

As part of this conversion, there were several key optimization requirements needed to eliminate downstream part post-processing and handling steps. One of the most significant to simplify downstream logistics was the need to match cavitation with package quantities. Currently, parts produced on their current molds had to be weighed to match packaging quantities which was both complex and expensive to operate. This change required the implementation of a higher cavitation 50-drop, unnaturally balanced layout design. In addition, the injection machines being used were not changing. Therefore, a compact mold design was necessary to ensure it would not exceed their existing limitations. 

The solution was an optimized Master-Series 50-cavity unnaturally balanced hot runner system (system # 5546071) featuring Mold-Masters proprietary iFLOW manifold technology.

iFLOW manifolds are manufactured from 2 separate pieces of steel where runner channels are CNC milled into each half. This unique manufacturing process allows our designers to have complete flexibility when optimizing hot runner performance and helps avoid design conflicts. Mold-Masters designers have the use of patented melt flow geometries, flow path options and runner shapes (including curved paths). This level of optimization just isn’t possible with conventional gun-drilled manifolds where designers are restricted to using straight runner channels with sharp 90° transitions in turns. Additionally, Mold-Masters compact Femto nozzle allowed for a tight 14mm pitch.

Our high-performance Master-Series hot runner system was able to meet all of the customers' expectations. The iFLOW manifold enabled optimization for the unnaturally balanced 50-cavity mold layout as it was able to achieve excellent mold fill balance of 99% @ 95% fill. This maintained the high molded part quality while matching the box quantity requirements. As a result, the customer was able to eliminate expensive downstream processing and packaging steps (cutting machines, weighing, handling) and the compact mold design ensured compatibility with their existing injection machines. Converting from cold runner to hot runner also allowed the customer to lower cycle times and eliminating scrap from cold runners reduced resin usage by up to 25%.