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3 Reasons Why Variable Speed Portable Chillers Are Trending In 2021

Process cooling is an essential piece of the puzzle needed for processing plastic.

Thermal Care offers a suite of powerful and efficient portable chillers (air-cooled, water-cooled and remote condenser models) for the plastic industry.  All of our units are reliable, easy to operate, packed with many standard features and built for dependable operation using an assortment of quality components. Weare proud to produce one of the best process cooling equipment systems in the industry.

A conventional portable chiller uses a compressor running at a continuous speed, also known as a fixed speed compressor.  Regardless of the requirements placed on it by the process load, the compressor speed remains at 100%.  Fixed speed chillers employ a “hot gas bypass” to maintain the demand on the compressor to avoid wide fluctuations in the coolant temperature delivered to the process for consistent output.

Compared to a typical chiller with a fixed speed compressor, the Thermal Care NQV series chiller with a variable speed compressor provides major power savings at partial loads.  This is particularly important in process applications which run varying loads that rarely use full capacity of the chiller.  Variable speed scroll compressor technology varies the compressor speed to match the process load.  This means the compressor slows down under part load conditions for peak performance and reduced power use.

Why go for the variable speed compressor chiller?

  1. You Want To Save Money On Energy Costs
    The variable speed scroll compressor technology, in conjunction with the PLC, constantly monitors the process and adjusts the compressor speed for peak efficiency and temperature control.  Since the compressor speed is automatically adjusted, the chiller works only as hard as necessary to provide optimum performance with significantly reduced power use.  Studies have shown that a 20% reduction in motor speeds can lead to 51% in energy savings.

    Typical ROI on variable speed compressor chiller = 12 ~ 18 Months
    NOTE: IF your heat load regularly operates well below the chiller’s available capacity, the NQV chiller with a variable speed compressor  would be extremely efficient in energy savings.
    **Variable Speed Portable Chiller Savings Calculator**Below is a chart of the electricity cost for the Western States that Hirate America covers.
    Reference: Choose Energy Electrical Rates By States
  2. You Want to Save Money On Installation
    Portable chillers are fully packaged systems housed in a single cabinet with mounted casters. They come with an integral tank and pumping system containing everything you need to provide chilled water to your process.  It’s a complete plug and play setup, which makes installation super easy.  Just place in your desired location, connect the water and power and you’re ready to go.
    This also provides flexibility on production as you can move the chiller from one machine to another with ease.
  3. You Want Smart Technology That Saves Time
    The NQV series portable chiller come standard with Thermal Care’s latest 7″ color touch screen with advanced PLC controls that provides real time diagnostics.  This enables you to troubleshoot and solve issues quickly, which saves valuable time and headaches.  This feature is a maintenance crew’s dream come true.
    Optional CONNEX4.0 technology allows remote monitoring and multi-unit system control with secure access and control to all your Thermal Care connected equipment so you can have confidence your process is running without issues.

Featured Specifications

Hirate America partners with Thermal Care, a leader in manufacturing of industrial grade water chillers, process cooling equipment and systems for applications worldwide.  As an ISO 9001 certified manufacturer, Thermal Care provides heat transfer equipment for over 50 industries and specializes in offering both standard and custom designed industrial process cooling solutions.

If you have any questions regarding portable chillers, please contact any of the Hirate America team members to provide a process cooling solution tailored to your requirements.

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3 Reasons Why You Need a Vision Mold Protection System for your Injection Molding Machine

3 Reasons Why You Need a Vision Mold Protection System for your Injection Molding Machine

On a regular basis, we hear from customers that they damaged their molds, which causes significant headaches, loss time and money.  When the mold goes down, it’s a race to fix or replace the mold since downtime can jeopardize your project and program.  It is important to be proactive in protecting your molds before any issues occur.  Below are 3 reasons why you should have a vision mold protection system for your injection molding machines.

1. Eliminate Mold Damage

The important factor in investing in a vision mold protection system is to protect your mold. The Sigmax system integrates directly into the I/O signal system controls of the injection molding machine with no lag.  The unit will monitor and detect improper positioning of slide cores and ejector pins and virtually eliminate catastrophic damage of these parts as well as the need for unnecessary ejections.  When there is a problem (e.g. detection failed ejection of part) system will show an error and prevent production from moving forward.  The system will require the operator to open the safety gate door and check for any sticking parts and all codes need to be cleared before restarting the machine.

 

 

 

 

 

 

 

 

 

2. Insert Molding

Insert molding is a process in which a preformed part, typically metal, is loaded into a mold and plastic is molded around this part.

The Sigmax vision system will be able to detect the following:

  • Missing insert(s)
  • Misaligned insert(s)
  • Double insert(s)

3.  Part Inspection – Short Shot

The Sigmax vision system will be able to detect short shorts, which is basically an incomplete part.  The Sigmax vision system will be able to detect sizes down to 0.001 inches or 0.25mm.  With this feature, our system will eliminate defects and crushed parts and in turn will be able to forecast shortages in production.

Every injection molder should have a vision mold protection system, but it would have to make financial sense.  There is a stigma that these vision mold protection systems are expensive, complicated to operate and setup is difficult.  The Sigmax vision mold protection system is easy to setup and operate and relatively inexpensive when compared against having to fix or even replacing your mold.

The ROI on a vision mold protection system is easy to determine: How much it will cost if a mold needs to be fixed or replaced?

Sigmax Vision Mold Protection continuously improves and innovates their products to be the best vision mold protection created specifically for injection molding machines and the plastics industry.

If you have any questions regarding Sigmax or any plastic process equipment, please contact any of the Hirate America team members to provide an automation solution tailored to your requirements.

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5 Things To Consider When Selecting Your Next Temperature Control Unit for your Injection Molding Machine

A temperature control unit (aka TCU) is an essential piece of equipment that is needed for processing plastic.  Think of a mold as the engine of a car, the TCU could be seen as the radiator to keep the engine cool.  Before we get into details on what you should consider before purchasing your next temperature control unit let’s review what it is and how it works.

 

What is a temperature control unit?

Temperature control units or TCU, are used to preheat the mold (aka tool) and regulate it at a specified temperature by recirculating water or oil.  This is to ensure the molding process is the same from the first part to the last part.  The TCU regulates the temperature of the mold so the process does not change either if it’s summer or winter, hot or cold ambient temperatures in the plant.  Oil is used for temperatures above 250F.  TCUs are used for injection molding machines, blow molding machines and extrusion lines.

How does a temperature control unit work?

On a cold start, the TCU heats up water or oil utilizing the heating elements and the pump recirculates the fluid between the mold.

If the mold gets too hot, the TCU opens a small valve as needed within the unit connected to a cooling tower or chiller water source.

 

 

5 Reasons to Choose Thermal Care’s Temperature Control Unit Over the Competition:

  1. Value

    Everybody wants the best deal and value proposition. Thermal Care’s TCU provides high-flow pumps (up to 10HP pump and flow up to 140 GPM) for more efficient cooling and better cycle times.  For the budget conscious, opt for the basic controller which is easy to operate yet effective for decades of operation.

  2. User Friendly and Easy to Use

    Four swivel casters and front facing supply and return pressure gauges make the unit extremely easy to use and see important information on the TCU.
    The controls are easy to access, view and operate.
    Basic controller: Designed for applications that require basic operation at a great price.
    Standard controller: Provides a wide array of operational and diagnostic information that is easy to access, view and operate. Unit alarms are easily reset on the control panel.
    The premium controller: Includes all the features of the standard controller plus an added level of system monitoring and control for the best user interface, ease of maintenance and troubleshooting when needed.

  3. Industry Leading Warranty and Support

    3 year parts, 3 year labor warranty
    5 year microprocessor parts warranty with $175 lifetime exchange policy
    Lifetime pump heater casting warranty and lifetime pump seal warranty
    24-hour service hotline support is best in the business providing your company with comfort knowing that the graveyard technicians won’t be left hanging.

  4. Easy Maintenance

    Maintenance technicians will love the tool-less easy access to the interior cabinet in less than a minute. Next day air shipping on spare parts is available when needed.

  5. Customization

We can customize our temperature control units to meet your specific processing needs:

SPI interface to sync with your injection molding machine and any other peripheral equipment.
Solid State Relay prevents having to replace contactors
Dual zone units allows 2 TCUs with one plug, heat exchanger and a modulating valve.
Stacking rack allows 2 TCUs to be stacked on top of each for space savings.

 

 

 

 

 

 

 

 

 

 

 

 

 

Thermal Care offers a suite of powerful and efficient mold temperature control units for the plastic industry. Each unit is reliable, easy to operate, and built for dependable operation using an assortment of quality components and is proud to produce one of the best process cooling equipment systems in the industry.

If you have any questions regarding top entry robots, please contact any of the Hirate America team members to provide an automation solution tailored to your requirements.

 

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Everything You Need to Know About Vision Mold Protection Systems

 

Everything You Need to Know About Vision Mold Protection Systems for your Injection Molding Machine

What is a vision injection mold protection system?

The Sigmax vision injection mold protection system is made specifically for injection molders in mind and integrates directly into the control systems for the injection molding machine so communication between systems is instantaneous for high-speed processing.

The ultimate goal for the Sigmax vision mold protection is to prevent mold damage, which leads to costly repairs and weeks or even months of downtime.  This is not good for any business especially if you’re running lights out.  The unit has many other useful functionalities for injection molding.

 

What type of injection molding machine can this be used on?

Vertical and horizontal molding machines, high-cavity molds, low-pressure foam molding, metal injection molding (MIM), die-casting, micro-molding, and other forming machines, regardless of the materials being molded or formed.

 

Is there a mold size limit?

No, there is no size limit as we have several options for camera lens sizes that can be scaled accordingly.

How many molded parts can be monitored?

We have monitored up to 128 cavities, dependent on the mold design.

Is it possible to monitor injection short shots? 

Yes, it possible to detect short shots of 0.001 in size (0.25mm).

Is high cycle molding possible with the Sigmax Vision Mold Protection system?

Yes, communication is instantaneous as this unit has the capability to monitor 1 second cycles.  

What if my parts are transparent?

Yes, it is possible to monitor transparent parts as the software allows for adjustment in sensitivity and shadows.

How can the Sigmax Vision Mold Protection System reduce molding cycle time?

The unit ties directly into the I/O signal system controls of the injection molding machine there is no lag. Since you eliminate the need for unnecessary ejections, production over a period of time will be much more efficient.

How easy is the installation?

The camera is magnetic so it can be attached above or below the mold.  Once the required input and output signals are established connection very simple. 

Can I use the Sigmax Vision Mold Protection System on multiple injection molding machines?

Yes, it is possible to use one system on multiple molding machines, but it is important to assure exact location of camera from the saved in the recipes.  The unit has the ability to save multiple recipe setups with different areas you want to monitor or different jobs/molds and easily re-accessed later, which makes this system very versatile.

How reliable is the Sigmax Vision Mold Protection system and what is the typical service life cycle?

 The unit can run problem-free for decades because there are no moving parts. The user interface is a proprietary standalone system that does NOT rely on any third party software like Microsoft Windows OS, you will not have to worry about automatic updates that may disrupt functionality and worse yet deal with viruses that may corrupt your hardware.   

 

What is the typical ROI on the Sigmax Vision Mold Protection System?

Repairs for ejector pins and slide cores can cost several thousand dollars, but if you have substantial enough damage to the mold the entire mold may need to be replaced.  Not only do you have to deal with cost of replacing the mold, but what would hurt the most is the downtime in production.  In this instance, the payback would be tenfold.

Sigmax Vision Mold Protection continuously improves and innovates their products to be the best vision mold protection created specifically for injection molding machines and the plastics industry.

If you have any questions regarding Sigmax or any plastic process equipment, please contact any of the Hirate America team members to provide an automation solution tailored to your requirements.

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3 Ways to Reduce Costs in Your Plastics Process Cooling Systems

 

Plastic processing has seen many changes over the years. We have seen significant advancements in process throughput and increased quality control as well as automation and controls. But one thing has remained surprisingly the same—the cooling systems. What most people do not realize is there are new technologies today that can reduce their industrial cooling system operating costs by over 40%.

Often overlooked or considered not as important as other parts of a plastic processing plant, process water cooling systems are gaining more attention as energy costs and concerns over water use continue to increase. There have been a number of advances in technology that provide increased efficiency to reduce production costs as well as global demand for power and fresh water.

Who doesn’t want to save a buck or two, every dollar savings counts when looking at overall operational costs annually.

1. Cut water use by 90% with Adiabatic Fluid Coolers.

Most plastic processing facilities have a cooling tower to provide cooling to hydraulics, chiller condensers, and other process equipment. A cooling tower has a fan and evaporates water to produce 85°F process water. While effective at providing cooling, it uses a lot of water and requires water treatment to control biological growth. Cooling towers also expose the process water to the atmosphere and then require constant filtering.

With limited resources and a heightened awareness of the need to reduce energy and water consumption, the use of fluid coolers has become a popular alternative to conventional evaporative cooling towers.

Similarly, a fluid cooler uses ambient air to cool the process water. However, this is done through a cooling coil and without exposing process water to the atmosphere. This method is effective but limited by the temperature of the ambient air. In most cases, the practical limit is a process of water temperature leaving the dry fluid cooler about 10°F warmer than the entering air temperature.

To expand the usefulness of fluid coolers as a replacement for evaporative cooling towers, manufacturers have added evaporative pads to their fluid coolers to pre-cool the warm summertime air through a process called adiabatic cooling. Adiabatic cooling occurs by evaporating water into the dry air entering the fluid cooler. As the air absorbs water, it is cooled and the cooler air is able to provide a consistent and stable output, leaving water temperature of 85°F to process.

 

 

 

 

 

 

 

 

 

 

 

Although this technology uses some water, the system is extremely water-efficient and only needed during peak summertime conditions. The result is as much as a 90% reduction in water use versus a conventional evaporative cooling tower. In addition, the water is fully evaporated and not recirculated, as is the case with a conventional cooling tower, so there is no need for water treatment. More on Adiabatic Fluid Coolers.

 

 

2. Reduce energy consumption up to 34% with variable-speed chiller compressors.

When plastics processes require water cooler than 85°F, a chiller is used. A chiller uses refrigerant, compressor and evaporator to remove heat from the process water and cool the process fluid to 50°F or so.

Compressors and the use of refrigerant have been around since the 19th century, and many different types of compressors are used, but until recently they all operated at one fixed speed

. A relatively new technology is variable-speed compressors. With this technology, energy use is reduced by slowing the speed of the compressor to just what is needed for the conditions.

When the compressor slows down, there is a reduction of cooling capacity. Most chiller system designs use the maximum possible heat load at 100% production capa

city of the process equipment to ensure there is always enough cooling capacity. In most cases, the production equipment is operating at much less than maximum capacity, so the chiller is ‘over-sized.’ A variable speed compressor is a great way to save this excess energy.

Power use is a “square relationship,” meaning that as the compressor speed changes, the power use changes as a square of the speed change. For instance, if a compressor operates at 80% of its maximum speed, it will use 64% of its full-speed power.

This technology is available in a wide-range of compressor sizes. In addition, the initial equipment cost premium for this technology, depending on the hours of operating and load profile, can pay for itself in 12 to 18 months. More on portable chillers and central chillers.

 

 

3. Dramatically cut chiller energy costs with free-cooling systems.

Considering the ever-increasing need for more efficient systems, the newest trend in central chiller system design is to combine the benefits of a variable-speed compressor with that of an adiabatic fluid cooler.

These hybrid systems use an adiabatic fluid cooler to cool the condenser of the chiller during the summertime, but when the outside ambient temperature is cool enough, the adiabatic fluid cooler directly cools the process water, which means the chiller turns off completely. This saves 100% of the electrical cost of operating the chiller, which is the most significant power consumption of any process cooling system.

The number of hours of free-cooling increases when the process fluid temperature is warmer. In many extrusion applications, the chilled water set point temperature is such that the chiller may only need to run 50% of the year.

 

Who doesn’t want to save a buck or two, every dollar savings counts when looking at overall operational costs annually.  

Thermal Care continuously improves and innovates their products to be the best process cooling equipment systems in the industry.

If you have any questions regarding top entry robots, please contact any of the Hirate America team members to provide an automation solution tailored to your requirements.

 

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Thank You For Visiting Us at the 2019 PLASTEC WEST (MD&W West)

We hope you had the chance to stop by both of our booths.
Our LS Mtron (LG Electronics) 550ton “The One Series” was a huge hit and had many compliments on how quiet and efficient it ran.
Just a recap, we provide full turn-key solutions for plastic processing:

  • Hyundai and LS Mtron – South Korean injection molding machines
  • Nissei ASB – One-step injection stretch blow molding machines
  • Motan – Central material handling systems, blenders and central drying
  • Dri-Air – Portable dryers and material handling systems
  • Thermal Care – Process water cooling systems
  • FIPA – End of arm tooling components
  • MAC – Conveyor belts, automatic box fill systems and resin bins
  • Sailor – High speed top entry robots & beside-the-press- custom automation systems
  • Yudo – Economical top entry robots and side entry robots
  • SRS Corp. – Beside the press, screenless granulators and dedusters
  • Sesotec – Metal detection, metal separation, magnets
  • ALPS – Leak detection for blow molding
  • SFM – Screws and barrels
  • Gammaflux – hot runner controllers
  • NGR – One-step shredder, extruder, pelletizer recycling system
  • Lindner – High throughput shredders and wash line systems
  • CMG – Granulators and shredders

Our latest product line brochure, which showcases all the products we represent along with some real case studies can be downloaded on our website Hirate America.   Please let us know and we’ll be happy to send you a hard copy as well.

In the meantime if you have any questions, or need assistance with your application, please do not hesitate to contact us. We’ll be more than happy to provide our expertise.

Again, thank you for considering Hirate America and we look forward to the opportunity of serving you.

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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PLASTEC WEST (MD&W West) 2019 Event

Happy New Year and hope you enjoyed your holiday!  It’s that time of year again and Hirate America (one-stop-shop for injection molding, blow molding, auxiliaries, extrusion and recycling equipment in the plastics industry).
PLASTEC West 2019 (MD&M West) will be held at the Anaheim Convention Center in Anaheim, CA on February 5-7.
We wanted to change things up a bit this year so we will be having and 2 separate booth locations!
Booth #3842 – Will be displaying our auxiliary equipment lines
Booth #4011 – Will be displaying and running our flag ship 550ton “The One Series” from LS Mtron (LG).

If you haven’t already get your complimentary expo admission by visiting:
www.plastecwest.com/special and use promo code SPECIALHIR33

We hope you get the chance to stop by our booths, meet the team, and see what new products we have for 2019.
Looking forward to seeing you there!

Our latest product line brochure, which showcases all the products we represent along with some real case studies can be downloaded on our website Hirate America.   Please let us know and we’ll be happy to send you a hard copy as well.

In the meantime if you have any questions, or need assistance with your application, please do not hesitate to contact us. We’ll be more than happy to provide our expertise.

Again, thank you for considering Hirate America and we look forward to the opportunity of serving you.

If you have a project that you would like to discuss, feel free to contact us below to schedule a free consultation.

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Announcement: Jason Sears Named President of Dri-Air Industries

Jason Sears has been named president of Dri-Air Industries, replacing Charlie Sears, Dri-Air founder and Jason’s father, who passed away recently.   The Board of Directors of Dri-Air made the announcement.

Jason has been an employee at Dri-Air for 30 years, beginning after school during his high school years learning such skills as welding, electrical wiring, painting, packing and machine assembly.   Building on this strong foundation for a future leader, Jason joined Dri-Air after earning his B.S. in Chemical Engineering from the University of Rhode Island in 1992.

He has held positions in engineering new products, designing equipment for new applications, technical troubleshooting, manufacturing and customer service. He has been Vice President of Operations for more than five years.

Remembering his father, a customer satisfaction legend in the plastics manufacturing industry, Jason said, ”Charlie Sears was a great mentor, embracing all the good characteristics of a principled, customer service oriented, honorable person.   Hard work and leading by example are valuable lessons I learned from my father.   After he created a succession plan, we continued to work together very closely as Dri-Air grew and advanced its success.” He added. “My commitment is to maintain Dri-Air at the same standards that have made it successful for 44 years…providing the best quality dryers that our customers deserve.   At Dri-Air, the customer always will come first.”

In his community, Jason Sears has focused on the STEM (Science, Technology, Engineering and Mathematics) movement, taking an active role in the First Robotics program at the middle and high school levels.   He has sponsored the Plastics Industry’s Plasti-Van at local schools.

Jason currently holds a position on the Plastics Industry Association Equipment Council and the NPE 2021 Content Committee, having participated in the NPE committee since 2015. He is also a member of the Society of Plastics Engineers.

Dri-Air Industries is the leader in compressed air and desiccant drying technology. The company offers a proven, patented 4-bed desiccant dryer design for faster drying of plastic pellets with no moving parts.   Applications include plastic dryers, resin blenders and material handling systems.

Hirate America partners with Dri-Air Industries Inc. if you need desiccant drying equipment.

Please contact us if you have any projects you’d like to discuss with us.

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Announcement: Santa Fe Machine Works, Inc. Names Don Smith as Sales Executive/Product Development Manager

Don Smith a fixture in the Plastics Industry for nearly 40 years has transitioned from singular Barrel sales, to Screw, Barrel, Valve sales, as well as repair services with Santa Fe Machine Works, Inc.

Fontana, California 5/1/2018 Santa Fe Machine Works today announced that Don Smith has been named as Sales Executive/Product Development Manager. Don will work with his long established industry contacts to sell them Screws, Barrels, Valves & a multitude of Repair services offered by Santa Fe Machine Works. Don will work closely with SFM Management to develop new products & services that will help Santa Fe Machine deliver its Customers the most robust product offering in the Industry.

“We are obviously very excited to bring Don Smith into Management with Santa Fe Machine Works. For decades we have enjoyed the level of service he gave us with Wexco & he is already a natural fit to our team.” Scott Kelly CFO, Santa Fe Machine
Don Smith will remain in Virginia with his wife Beth, whom he has been married to for 28 years. From his location, Don will be able to focus his energy on developing new relationships with Extrusion/Injection OEM’s and Processers as well as adding enhanced service levels to our existing Customers around the world. Having worked his way from the Production floor, up to Management with Wexco Corp. his knowledge of the Manufacturing process & the balance between it and Sales will make him an asset to both departments within Santa Fe Machine. His expert understanding of the Barrel Market will allow Santa Fe to increase its market share in the Industry.
“When I was told that Don had been hired by Santa Fe, I instantly knew he was with the right company, who will respect his knowledge & ability to take them into a new expansive group of customers.” Fred Mellberg, Japan Steel Works Inc. (JSW.)

Don will be in Santa Fe Machine Works’ booth #W116 at ”NPE2018:The Plastics Show” in Orlando, Florida May 7-11, 2018. He is very eager to meet face to face with many of his friends in the industry & introduce them to the “concierge” style of service & dedication to its customers Santa Fe has offered for over 95 years. Don looks forward to an exciting time of discovering opportunities for Santa Fe Machine to capitalize on new areas of Market Share & deepening existing relationships with Processers & OEM’s alike.

Hirate America partners with Santa Fe Machine Works if you need screws and barrels.

Please contact us if you have any projects you’d like to discuss with us.

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Press Release: Thermal Care Next Generation Pumping System Controller

Thermal Care’s second generation of advanced pump system PLCs can expand to control up to 15 pumps and 8 cooling towers, including VFDs and up to 3 process zones, each with up to 4 fluid circuits. Easy to navigate with its standard color touch screen, all the information you need to run your process is available at your fingertips for quick access and management of parameters including pumps and alarms. An added benefit allows you to customize the names of all devices for easy identification. Multiple user safeties, warnings, and alarms, and pump and fan running hours are displayed along with the ability to change lead fans or pumps. If you are looking for peace of mind, the pump system controller is CONNEX 4.0 ready and can provide secure detailed system status information via a remote mobile device or computer with an internet connection. When used in conjunction with Thermal Care s extensive line of heat transfer equipment, the most the most energy efficient, operationally intuitive, and productive systems can be provided.

 

MAIN SCREEN

FAN SCREEN

DIFFERENTIAL PRESSURE SCREEN

DIVERTING VALVE SCREEN

TRENDING SCREEN

 

Thermal Care continuously improves and innovates their products to be the best process cooling equipment systems in the industry.

If you have any questions regarding top entry robots, please contact any of the Hirate America team members to provide an automation solution tailored to your requirements.