5 COMMON PROBLEMS IN PLASTIC MOLD COOLING SYSTEMS
Unstable Mold Temperature
One of the most common problems in plastic mold cooling systems is continuous mold temperature fluctuation during the injection process. The most noticeable symptoms include prolonged cooling time, inconsistent molding cycles, and unstable product quality. Products may experience warping, uneven shrinkage, or dimensional deviations from the original design.
The main causes include chillers with insufficient capacity or the use of traditional on/off control systems, which result in frequent changes in cooling water temperature. In addition, uneven water flow distribution among mold cooling channels causes certain areas to cool rapidly while others retain excess heat.
As a result, molding cycles are extended, scrap rates increase, and molds deteriorate more quickly due to uneven thermal stress over time.
Insufficient Cooling Water Flow and Pressure
Insufficient cooling water flow and pressure is a common issue in many plastic manufacturing plants, especially in systems that have been operating for long periods. A typical situation is weak water supply to the mold, leading to “cold channels – hot channels” within the same mold.
This problem may result from pumps that are not properly matched to actual load requirements, suboptimal piping design, or scale buildup and blockages within the water circulation system. When water flow is inadequate, heat exchange efficiency is significantly reduced, causing the cooling system to perform poorly.
Consequently, molds cool unevenly, localized product defects occur, and it becomes difficult to maintain consistent quality across production batches—posing a major risk for manufacturers producing large volumes or supplying export markets.
High Electricity Consumption
High electricity consumption is another common problem in plastic mold cooling systems that many businesses only recognize when electricity costs rise sharply. A clear sign is when the chiller operates at full load continuously, even when actual cooling demand is relatively low.
The primary cause is the use of traditional air-cooled or water-cooled chillers with non-inverter compressors that cannot adjust capacity according to the load of each injection molding machine. As a result, the system operates with excessive capacity while still consuming large amounts of electricity.
Over time, production costs increase, profit margins shrink, and companies face greater difficulty competing on price in the market.
Unstable 24/7 Operation
In industrial manufacturing environments, particularly in the plastic industry, cooling systems are often required to operate continuously 24/7. However, many plants experience frequent chiller alarms, unexpected shutdowns, or temperature loss during production shifts.
The causes may include equipment not designed for continuous operation, lack of redundancy, or poor heat dissipation in hot and humid factory environments. When the cooling system becomes unstable, the entire production line is disrupted.
The consequences include production downtime, lost time restarting the line, delayed delivery schedules, and negative impacts on customer trust and business reputation.
Difficulty in Expansion and Customization When Production Capacity Increases
When factories expand their scale, add more injection machines, or increase the number of molds, many existing cooling systems can no longer meet the required load. As a result, some companies are forced to replace the entire chiller system, leading to significant investment waste.
The main reason is inflexible chiller design that does not account for future expansion from the outset. This is one of the common problems in plastic mold cooling systems that is often overlooked during the initial system design phase.
COMPREHENSIVE SOLUTIONS FOR PLASTIC MOLD COOLING SYSTEMS
To address the issues above, businesses need to select cooling solutions based on core principles: capacity matched to actual load, precise temperature control, energy efficiency, stable 24/7 operation, and scalability for future expansion.
For the plastic industry, White Cool DC Inverter chillers have been developed as a specialized solution for injection molding plants and production lines with multiple molds and machines. The system allows precise temperature control down to ±0.5°C, ensuring uniform and stable mold cooling.
By applying DC Inverter technology, White Cool chillers can reduce electricity consumption by 30–45% compared to traditional systems, while optimizing water flow and heat exchange efficiency. The equipment is designed for durable 24/7 operation in hot and humid factory environments and can be customized in capacity and configuration for each specific project.
This solution helps plastic manufacturers reduce product defects, shorten molding cycles, optimize electricity costs, and extend the lifespan of both molds and injection machines.
CONCLUSION
The common problems in plastic mold cooling systems, such as unstable temperature, inadequate water flow, high energy consumption, and limited scalability, directly affect production efficiency and operating costs. Investing in the right chiller solution from the beginning plays a crucial role in a plastic factory’s long-term operational strategy.
If your business is experiencing issues with mold temperature, electricity consumption, or system stability, reassessing your cooling system is a necessary step.
Contact White Cool for consultation on chiller solutions for the plastic industry and to calculate the most suitable capacity and configuration based on actual factory conditions.