Production of plastic lids is a complex technological process that involves the use of hot raw materials for molding. Cooling is a crucial stage in ensuring the quality of the products, and this is where a chiller comes in. The chiller is a special device that can rapidly cool the plastic to the desired temperature. Controlled cooling speeds up the process of lid manufacturing, helps achieve smoothness and the required density of the product, and eliminates defects such as bubbles, unevenness, or uneven color. The chiller works on the principle of heat transfer through the passage of a refrigerant through its three main elements: a compressor, a condenser, and an evaporator.
The principle of operation and design
To understand what a chiller is, let's look at how it functions and works. The principle of its operation is based on the physical process of heat transfer during the passage of the refrigerant through the structure. It is based on 3 elements:
- ✅ compressor;
- ✅ capacitor;
- ✅ vaporizer.
An evaporator is responsible for removing heat from cooled objects, through which a refrigerant and water are passed, which acts as a coolant. Freon, antifreeze or ethylene glycol can be used as a refrigerant.
During the boiling process, the refrigerant absorbs the energy of water, and in a gaseous state is supplied to the compressor. There, hot steam begins to compress, heating up to 80-90 degrees.
Next, freon is fed into the condenser, where it is cooled by the cold air flow. The final cycle is reduced to the fact that the refrigerant from the heat exchanger is fed into the desuperheater. Its temperature drops, and it again turns into a liquid form, after which it enters the filter drier, where moisture is evaporated from it. Then the refrigerant enters the thermal expansion valve, after which its pressure decreases. At the outlet, the refrigerant is in the form of a vapor combined with a liquid. The mixture is fed further to the evaporator, where the refrigerant boils and turns into vapor. In the gaseous state, it leaves the evaporator, which sets the start of a new cycle.
Types of equipment
Settings are available in a wide variety. They differ from each other in configuration and technical characteristics. First of all, chillers are usually classified according to the principle of cooling and the following varieties can be distinguished:
- ✅ air ("Air-Water") – the condenser is cooled by airflow;
- ✅ water ("Water-Water").;
- ✅ with film-type evaporators. Such models are mainly used in food production – chillers for water cooling.
It is customary to classify installations into groups according to the technical characteristics of the main components. So, according to the type of refrigeration cycle, the equipment is divided into: absorption and vapor compression models. Compressors can be rotary, piston, screw, scroll. Fans for a complete set are used axial or centrifugal. In addition, chillers can be equipped with a heating option, for this they are equipped with a heat pump.
How to choose equipment
There are many parameters to consider when selecting industrial chillers for plastic injection. First of all, the type of injection molding machine and its availability for the integration of a certain type of cooler should be taken into account.
Even when choosing, you should take into account the temperature regime for the manufacture of plastic products and, in general, production volumes. In accordance with these characteristics, it is worth ordering a chiller suitable for power and functions.
An important indicator is also the level of cooling capacity. It is necessary for the chiller to be 10-15% higher than the maximum production rate. In this case, it will not be necessary to operate the equipment at maximum capacity, and the installation will wear out to a lesser extent.
Some fancoil chiller models use cold from the environment rather than from the compressor during the cold season. This option is typical for devices with free cooling. Such chillers are suitable for industries where polymers are processed at temperatures higher than ambient t◦C.
Benefit of contacting us
Summarizing, we note that the use of chillers in the production of plastic bottle caps significantly helps to improve their quality and speed up manufacturing. Without a cooler, the number of defective products increases, and manufacturing processes slow down, its volumes decrease. For this reason, it is worth ordering plastic lids from companies that use up-to-date technologies when equipping production lines. In Ukraine – this is the Preform Factory.
We have installed modern equipment that allows us to guarantee the quality of our plastic products and the production of large batches of goods in a short time. We ourselves purchase raw materials, prepare and paint them, and provide control at all stages of production. In addition, favorable prices for orders are available to our customers. We are engaged in wholesale deliveries and have established our own production, which allows us to reduce the final cost of goods.