How to Choose Coil Heaters to Use in Hot Runner Systems?

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Choosing a suitable coiled heater for hot runner systems is crucial to ensure efficient and consistent heating and optimal performance. So today, let’s talk about selecting coil heaters for hot runner systems and what you need to pay attention to on this page.

 

What are the hot runner systems?

 

The hot runner system is an advanced plastic injection molding technology that can transport molten plastic from the machine to the mold cavity and keep the plastic molten during the entire process.

 

What are the heating elements?

 

Heating elements are usually composed of resistance wires, MgO insulation, and sheath material, standard sheath materials are INCOLOY ®, steel, copper, and stainless steel (type 304), etc. Their primary function is to convert electrical energy into heat energy to meet people’s needs. If you want to know more, please click here.

 

What is the relationship between them?

 

The relationship between hot runner systems and heating elements is a close one. The heating elements are connected to the temperature controllers, responsible for transferring heat to the design and ensuring the plastic remains molten throughout the injection molding process.

 

In hot runner systems, heating elements are primarily applied to the following parts:

 

  1. Hot runner manifold. The hot runner manifold is the central part of the hot runner system, responsible for conveying the molten plastic from the injection machine nozzle to the individual hot runner nozzles. Heating elements are embedded within the manifold, providing heat to maintain a constant temperature for the molten plastic throughout the conveying process.

 

  1. Hot runner nozzles. The hot runner nozzles are located between the hot runner manifold and the mold cavities, responsible for injecting the molten plastic into the mold cavities. The nozzles also contain heating elements to ensure that the plastic remains molten before entering the mold cavities.

Thus, heating elements directly impact the molten state of the plastic, molding quality, and production efficiency. Therefore, maintaining and managing the heat runner heater is critical to ensuring the proper operation of the hot runner system.

 

What facts do you need to pay attention to?

 

Choosing coil heaters for hot runner systems requires considering several factors to ensure that the selected heater meets the production requirements, maintains the plastic’s molten state, and provides product quality. Here are some key factors to consider when choosing a coil heater for a hot runner system:

 

  1. The material of the coil heater plays a crucial role in heat transfer efficiency and durability. High-quality materials like nickel-chromium alloy provide excellent thermal conductivity and corrosion resistance.

 

  1. Power and voltage. Select an appropriate heater power and voltage based on production requirements and equipment constraints. Excessive force may cause rapid heating, affecting the molten state of the plastic, while insufficient power may not meet production demands.

 

  1. Heater size and shape. Choose a coil heater size and shape that matches the hot runner system components, such as nozzles and manifolds. The heater should fit the details correctly, ensuring effective heat transfer and even heating.

 

  1. Temperature control. Opt for a coil heater with reliable temperature control capabilities, ensuring that the entire hot runner system maintains the proper temperature during molding. Accurate temperature control contributes to improved product quality and production efficiency.

 

  1. Heating uniformity. Ensure that the chosen coil heater provides even heating to avoid localized overheating or cooling. Uniform heating helps maintain the plastic’s molten state and reduces defects during production.

 

  1. Select a coil heater that complies with safety standards, ensuring the security of operators and equipment. Protective measures and overheating protection features can reduce safety risks.

 

  1. Maintenance and replacement. Choose a coil heater that is easy to maintain and replace, allowing quick relief and reducing downtime.

 

  1. Manufacturer’s reputation and support. Select a coil heater from a reputable manufacturer with excellent customer support and technical assistance. A reliable supplier can help ensure product quality and provide proper installation and maintenance guidance.

In summary, when selecting a coil heater for a hot runner system, multiple factors must be considered to ensure that the chosen heater meets production requirements, maintains the plastic’s molten state, and provides product quality. Working with a reliable supplier for high-quality products and technical support is essential.

The above tips also apply to other coil elements, such as immersion heaters and so on. Click here to know about the immersion heater’s meaning.

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What suggestion can we offer you?

 

How to choose coil heaters to use in hot runner systems? Share our video with you, we have some professional suggestions for you.

Spring coil heaters are the most cost-effective choice; some customers usually ask for a straight coil heater to keep inventory. They will make subsequent shaping work themselves to respond to customer requirements quickly.

The spring coil heater has several disadvantages, as below.

 

  1. Due to heat expansion, the top and bottom of the coil heater tend to lift from the nozzle body after long-term operation.

 

  1. These spring coil heaters are produced with varying turns, the contact area between the spring coil heater and hot runner bushing is linear contact, and Its Effective contact area is just 25%-33%. So, there is a significant heat loss.

 

But the other kinds of coil heaters perfectly solve the problem; they exhibit an exact fit of the internal diameter and excellent heat transfer with brass or stainless-steel barrel. As Kappa coil heaters and the pressed-in brass coil heater both provide a uniform temperature distribution in the nozzle and good durability. The Kappa series features a thread on one end of the outer sleeve. so that Kappa series coil heaters are easily replaced with a fixture pulling it out from the nozzle. Pressed-in brassed coil heaters take up smaller mold space, The Minimum thickness of the brass wall is 2.0mm.

The last one is embedded in nozzle coil heaters, it takes up no mold space and has the best heat transfer, but the heater maintenance is trouble.

In total, I think The best coil heater is pressed in brass coil heater, it offers the best performance. Anyway, every coil heater has its advantage and disadvantage. It all depends on your requirements.

If you have any confusion about this, you can contact us. We not only provide the best price but also provide consulting services.

 

 

Why choose Hasteco as your reliable relationship?

 

  1. Various choices. Hasteco engineers developed several kinds of coil heaters: spring coil heaters, pressed-in brass coil heaters, Kappa series coil heaters, Axial clamp coil heaters, and embed-in-nozzle body coil heaters. Besides, we also offer a professional bending machine for winding coil heaters.

 

  1. The competitive price. Our coil heater elements price is less than other coil heater companies.

 

  1. Quality assurance. We are a coil heater element maker that makes high-quality and has many years of production and sales experience.

 

  1. Perfect seller service. If there are any problems, contact us on time, and we will reply immediately.

 

Contact us by clicking the button below.

 

 

 

Sales representive Luke

Luke

As the devoted CEO of Hasteco, I've spent countless years nurturing my passion for heating elements. Warmly inviting you to connect & collaborate for cozy, tailor-made solutions. Get in touch!

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