Tag Archives: Injection moulding

Why Accurate Chiller Sizing Matters

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A chiller that’s slightly too small for the job doesn’t usually fail outright. It just runs harder than it should, all the time, and the cost of that gets absorbed quietly into cycle time, part quality, and your energy bill.

Here’s how an undersized chiller actually affects your process, and what to check if you suspect yours might be under-specified.

Why Chiller Sizing Gets Overlooked

Chillers are often specified early in a project, sometimes before the full tooling and production plan is finalised. A chiller sized for one job can end up serving several moulds over its lifetime, some far more demanding than the original spec accounted for.

Because a chiller rarely fails completely when it’s undersized, the problem tends to hide in plain sight. It just works harder, for longer, without ever throwing an obvious fault.

How It Actually Affects Your Process

1. Longer Cycle Times

If the chiller can’t remove heat from the mould fast enough, cooling time has to stretch to compensate. This adds seconds to every single cycle, which adds up to a significant amount of lost output over a full production run.

2. Inconsistent Mould Temperature

An undersized chiller struggles most under peak load, which means mould temperature can drift during long runs even if it looked fine when the process was first set up. This is a similar pattern to what we’ve covered in common causes of inconsistent moulded parts — a slow drift that’s easy to miss until it shows up in the finished product.

3. Warping and Dimensional Issues

Uneven or insufficient cooling changes how a part shrinks as it solidifies. This often shows up as warping, sink marks, or dimensions that fall outside tolerance, especially on parts with thicker sections that need more heat removed to cool evenly.

4. Higher Running Costs

A chiller working constantly at or near its limit draws more power than one sized correctly for the load. Over a year of continuous running, that difference in energy use adds up. It also puts extra wear on the compressor from running flat out.

5. Shortened Equipment Life

Compressors and pumps designed to cycle on and off wear differently to ones running continuously under strain. An undersized chiller often needs replacing sooner than one properly matched to the load it’s cooling.

How to Check If Yours Is Undersized

Start by comparing your chiller’s rated cooling capacity against the actual heat load of the tools it’s running. This means mould size, material type, wall thickness, and cycle rate, not just the tonnage of the moulding machine itself.

Watch for cycle times that have crept up over time without a clear cause. Also watch mould temperature readings that vary more than expected across a long run. Both are common signs the chiller is being asked to do more than it’s rated for.

Getting the Sizing Right

Chiller sizing depends on more than machine tonnage. It needs to account for the specific tools being run, ambient conditions, and how much headroom you want for future tooling. Our range of chillers is specified against your actual production requirements, not a generic match to machine size.

Get in Touch

If you suspect your chiller might be undersized, or cycle times have been creeping up without an obvious cause, we’re happy to take a look at the numbers with you.

Geiger Handling UK Ltd
Phone: 01782 630555
Email: sales@geigerhandling.co.uk
Web: geigerhandling.co.uk

Quality Matters: How to Choose Equipment Effectively

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It’s tempting to judge a piece of equipment by its price tag, or by where it was made. Neither tells you as much as people assume. Expensive equipment can fail early, and competitively priced equipment can run reliably for years. The price and the country of manufacture were rarely the actual reason either way.

Here’s what we think actually determines whether equipment is worth buying, based on what we’ve seen across the range we supply.

Why Price and Origin Are Poor Shortcuts

The plastics equipment market has changed a lot over the last twenty years. Manufacturing that used to sit almost entirely with Swiss, German and Italian suppliers has shifted. Some of that ground has moved to producers in China and elsewhere in Asia, alongside genuine quality improvements.

The automotive industry has gone through the same shift, and it’s a useful reference point. Components once dismissed on origin alone are now standard in vehicles built to strict safety and reliability requirements. Origin stopped being a reliable tell for quality a while ago, in that industry and in ours.

Price works the same way. A higher price doesn’t guarantee better engineering, and a lower price doesn’t guarantee corners have been cut. It depends entirely on the specific manufacturer, not the price bracket or the country stamped on the nameplate.

What Actually Determines Quality

1. Manufacturing Consistency

The real question isn’t what a product costs, but whether it’s made to a consistent standard, run after run. A manufacturer with tight tolerances and proper quality control produces reliable equipment regardless of price point. One without those controls can produce inconsistent results even at a premium price.

2. Track Record on Similar Equipment

Performance over time matters more than a spec sheet. We look at how equipment actually performs in the field before representing it, not just how it’s marketed. This is why some of our supplier relationships go back many years, and why we’ve moved on from others when we’ve needed to, rather than sticking with a brand purely on reputation or history.

3. Whether the Supplier Backs the Product

This is often the real difference between a good purchase and a costly one. Equipment backed by proper technical support, available spares, and a reliable supplier who stands behind it holds up a lot better over time than equipment bought purely on price with no support behind it.

4. Fit for the Application

Even well made equipment can be the wrong choice if it’s not suited to the specific application it’s being used for. Getting this match right often matters more than the brand or the price point attached to it.

How We Approach This

Some of our supplier relationships go back decades, built on the kind of trust that only comes from years of working together and standing behind what’s supplied. Where that partnership still delivers the right equipment at the right price, we stay with it. 

We’ve brought in ranges like FGS end of arm tooling because we assessed them properly and found them genuinely competitive, not because they were the cheapest option going, but because of their robust quality. 

Questions Worth Asking, Regardless of Price

  • Has this equipment got a genuine track record, or is it unproven?
  • Is the supplier able to back it with support and spare parts?
  • Is it actually suited to the application, not just the budget?
  • Are you buying from someone who’s assessed it properly, or just passing on the lowest quote?

Get in Touch

If you’re weighing up equipment or parts and want an honest view on what’s actually a good fit, we’re happy to talk it through, whatever the price point.

Geiger Handling UK Ltd
Phone: 01782 630555
Email: sales@geigerhandling.co.uk
Web: geigerhandling.co.uk

Common Causes of Inconsistent Moulded Parts

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Same machine. Same settings. Same material, on paper. Yet today’s parts don’t quite match last week’s. This is one of the most frustrating problems in injection moulding, because nothing on the machine has changed.

Here are five common causes of inconsistent moulded parts, and how to track them down.

Why “Nothing Changed” Is Rarely True
The machine is usually the last thing to blame. It’s simply reacting to small changes elsewhere in the process. These changes are easy to miss, since nobody touched a setting.

Consistency depends on several things staying stable at once: material condition, mould temperature, cooling time, and even factory conditions. A shift in any one shows up in the part.

5 Causes of Inconsistent Moulded Parts

  1. Material Moisture Variation
    The most common cause. Inconsistent drying means the material going into the machine changes slightly, batch to batch. A dryer running to a timer, not a confirmed dew point, is a frequent source of this drift.
  2. Regrind Ratio Changes
    An uncontrolled regrind ratio shifts part properties between batches. Reprocessed material often flows differently to fresh material.
  3. Mould Temperature Drift
    A mould running a few degrees off target changes shrinkage, warping, and surface finish. Often caused by a temperature control unit no longer holding its set point, due to scale build-up or an undetected fault.
  4. Inconsistent Cooling Time
    Small cycle time variation changes how long a part cools before ejection. Parts eject at slightly different temperatures, showing up later as dimensional variation.
  5. Ambient Environmental Changes
    Factory temperature and humidity shift with the seasons. A process dialled in during cool, dry weather can behave differently once the factory warms up.

How to Track It Down
Check what actually changed, not what you assume didn’t:

  • Check moisture readings against spec, not just the drying schedule
  • Check mould temperature against its set point, not just power status
  • Review cycle time logs for small drift
  • Compare a “good” batch against a “bad” one using data, not memory

Why It’s Worth Chasing Down
Inconsistent parts cost more than scrap alone. They erode confidence in a trusted process, and often lead to over-adjusting machine settings, which creates new problems on top of the original one.

See the Plastics Technology guide to resin drying if moisture looks like a factor. Also worth reading: our piece on material contamination, a related issue with different root causes.

Get in Touch
If your process has drifted and you can’t pin down why, we’re happy to help. Sometimes it’s a quick check; sometimes it’s worth a site visit.

Geiger Handling UK Ltd
Phone: 01782 630555
Email: sales@geigerhandling.co.uk

Geiger Handling speed up production for Malton Plastics with Wemo robot

Malton Plastics recently invested in a new 350 ton Demag to fulfill their ever increasing production demands, along with this they took the decision to invest in a linear robot for the removal of mouldings from the press , Geiger Handling supplied a turnkey solution of a Wemo E-design robot safety guarding and conveyor belt . Since installation Malton have seen an increase in production output and quality due to stable cycle times compared to having the machine manned by an operator

To read more please follow this link

Investment into New 350 Tonne Injection Moulding Machine