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Hot Runner Maintenance

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Hot runner maintenance covers preventative maintenance, troubleshooting, training, repairs, diagnostics, and cable/connector issues.

Click on this link to examine the Mold Making Resource break down on the benefits of hot runner systems.

Highpoints of hot runner systems:

• Ability to minimize gate vestige

• Uniform wall thickness

• Lower cycle times

• Less waste

• Reduction or elimination of knit lines

• Great for high cavitation molding

• Often the only method for micro-molding. The center-to-center distance of the hot runner tips is as little as 17 mm.

• Standardization of components can mean significant savings in material and manufacturing

• Many large molds rely exclusively on hot runners. Cold runners cannot meet the demands

You see it is all integral; the pieces of training, just like the information on what should be checked and maintained, the why, is all tied together.

In-house maintenance and repair mean a faster and more cost-effective turn around. It is good business and makes logical sense. Packing up and shipping out equipment and then waiting endlessly for it to be returned and paying an outside vendor for transport and an outsourced shop for the repair; costly. Further, keeping a shop on schedule is hard enough without these types of extensive delays.

If done properly, the how and why training will help your technicians be aware of possible issues before they even occur…again, applying that practical knowledge gained in training.

Your in-house maintenance team will also benefit from the personal skill development, as well, meaning increased confidence, and professionalism.

• Crucial Training Points

Mold Making Technology breaks down some of the basics in cleaning and repairing a manifold within a typical hot runner system:

• Map out systems (ohmmeter) for position verification of thermocouples and heaters.

• Perform heater and thermocouple resistance and connectivity checks and replacement. If a heater or thermocouple has failed, compare its resistance to “good” thermocouples to see if other are close to failing.

• Verify correct thermocouple operation/ location and replacement.

• Route (to connectors) and splice wires correctly.

• Disassemble and clean valve gates (valve pins, seals and cylinder components).

• Inspect and verify tooling conditions, and check manifold stack dimensions for proper preload. Measure components at both room temperature and operating temperature and record how long it takes to “soak” the tool before fully expanded. This is the soak time you need to use when setting the tool in production.

• Perform comparative (cavity-to-cavity) dimensional analysis on nozzle and gate tip heights.

• Remove, clean and reinstall fixed (thermal) gate tips (sometimes done in the press).

Spark Industries has created a guide for new mold-making and molding professionals on hot runner maintenance training. We hit some highlights below but you can check out the full piece here:

The Production Ready Check-List can be obtained here: Hot-runner-maintenance-training


Hot Runner Troubleshooting

Hot Runner Troubleshooting First, Staying Out of Trouble MoldMaking Technology® and Plastics Technology magazines published articles about hot runner troubleshooting that included the importance of proper hot runner system startup. While this blog is about troubleshooting, it is fair to say that the best way to get out of trouble is to stay out

Hot Runner Maintenance Guide

Preparing for Production - Hot Runner Maintenance Guide This guide includes the blog post below and an adjoining slide deck. The blog post below is a reference guide with links to detailed explanations and visual examples we have compiled over the years (photos and videos). Use the adjoining slide deck for a speedy review

Common Hot Runner Cable Connection Problems

Common Hot Runner Cable Connection Problems Hot Runner Connector Anatomy Simple fixes can result in significant differences in your manufacturing process. You do not have to give in and just accept some common aggravating problems on the manufacturing floor. You may not think it’s worth changing some of the issues mentioned here. But what if

Minimizing Costs and Simplifying Hot Runner Repair

How will you minimize downtime and costly hot runner repair in your shop? The answer isn’t as complicated as you might think…here’s how Fast Heat by Spark Industries will help! You already know preventive maintenance is critical to the success of your shop. There will always be some amount of hot runner system repair, but

CableXChecker®: Diagnose Hot Runner Cable Issues

CableXChecker® - Effectively Getting to the Root of the Problem Spaghetti bowl?! That’s right…spaghetti! That’s what all the wires and cables inside a press might remind you of…and have you looked closely at all the pins and cables making up a hot runner system? CableXChecker® gets you to the root of the problem! Plastic injection

Hot Runner Maintenance Training

Hot Runner Maintenance Training Needs to Include Why Not Just How Onboarding and training new employees on why things are done a certain way and not just how is critical in hot runner temperature control and proper hot runner system management. What does onboarding and training have to do with hot runner controls? First,

By |2024-03-29T15:56:35+00:00November 3rd, 2021|Hot Runner Maintenance, Injection Molding Best Practices|Comments Off on Hot Runner Maintenance Training

Fast Heat’s CableXChecker®: Hot Runner Cable Testing

Hot Runner Cable Testing - So Much Easier! Hot runner cable testing can be a tedious process. The traditional way of testing hot runner cables uses an ohmmeter or multimeter. The problem is that when cables are “set aside” in the “not-sure-what’s-wrong-with-it pile,” somebody has to troubleshoot the cables to see if they are faulty.

By |2024-03-21T18:51:23+00:00November 15th, 2019|Hot Runner Maintenance, Injection Molding Best Practices|Comments Off on Fast Heat’s CableXChecker®: Hot Runner Cable Testing

Hot Runner Maintenance – Fast Heat’s MoldXChecker®

Hot Runner Maintenance - A Better & Safer Way! Hot runner maintenance can be a challenge. You look for dead shorts caused by pinched wires, open circuits, and you would want to measure the resistance of the heaters to ensure they are in a healthy range. Let’s start by measuring the resistance of the

By |2024-03-22T11:47:30+00:00November 15th, 2019|Hot Runner Maintenance, Injection Molding Best Practices|Comments Off on Hot Runner Maintenance – Fast Heat’s MoldXChecker®

MoldXChecker®: Hot Runner Diagnostics

Hot Runner Maintenance Using the MoldXChecker® Just like you would connect your hot half to a hot runner controller, you can now connect to the Fast Heat MoldXChecker®. If you’re wise and use the Mold Checker in the tool room, you would also know if you had an open heater. Waiting until you have a

By |2024-01-16T18:13:04+00:00November 15th, 2019|Hot Runner Maintenance, Injection Molding Best Practices|Comments Off on MoldXChecker®: Hot Runner Diagnostics

Hot Runner Cable Testing

Manny Diaz invented the Fast Heat CableXChecker® because of practical problems he experienced on service calls. It took too long and was too easy to make a mistake when checking for zone continuity and shorts (most people do not check for shorts) within hot runner cables. The CableXChecker® saves time (about 15 minutes per

By |2024-03-22T12:09:02+00:00November 15th, 2019|Hot Runner Maintenance, Injection Molding Best Practices|Comments Off on Hot Runner Cable Testing


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