Case Story Car Parts

A major Eastern European manufacturer of plastic parts for the automotive sector tested the Dynamico Syncro and these are the results: increased productivity and reduced cycle times.

Customer’s Needs

The company’s core challenge was directly related to profitability: the mold cooling time, which typically accounts for 40% to 80% of the total cycle time. Optimizing this phase is paramount, as a shorter cooling time directly reduces part cost (€/part) and significantly boosts productivity (parts/h).

To achieve this critical productivity increase and enhance overall manufacturing efficiency, customer opted to implement Frigel's cutting-edge Dynamico Dual Zone Dynamic Mold Temperature Control technology, choosing the Dynamico DYD 260 HP VF unit (Dual Zone with High Pressure Pumps).

The Dynamico line is prominently promoted as the "AI-Assisted Mold Profit Booster," engineered to directly supersede any conventional Thermal Control Unit (TCU). The compelling factors that drove the customer’s decision for Dynamico were the unit’s unique capabilities:

• Cutting Cooling Time: It achieves this by delivering exceptionally high flow rates—up to five times greater than standard TCUs—thereby dramatically improving the heat transfer coefficient.
• Facilitating Dynamic Control: Its Dual Zone feature enables precise, independent temperature settings for each mold half. This control is synchronized with the molding cycle.
• Guaranteeing Rapid ROI: By achieving maximum productivity with only minimal capital expenditure (CAPEX).

Strategy, goals and results

The customer proposed Frigel to test the Dynamico DYD in Syncro mode on a technical product, a specific car part.

Part & mold details:
The challenge to be overcome was ensuring a high level surface finish of the part, reducing the cycle time. 
The unit was digitally connected to the mold via an external switch, which is essential to have the syncronization between Dynamico unit and the injection molding machine.

The customer’s operators guided by the innovative software designed by Frigel, were able to carry out the unit’s commissioning phase independently. Thanks to an extremely straightforward step-by-step procedure, it was easy to identify the optimal recipe; once saved, it can be retrieved at any time in the future.
 

The final results

In the end, the customer made a significant, sustainable improvements to its injection molding process, thanks to  our Dynamico DYD100VF unit  implementation in Syncro mode. In details: 

• +41% increase of productivity
• -27% cycle time reduction
• 2,5h recipe fine tuning.

Syncro premium function, available with VFD HP pumps, optimizes cooling performance by delivering a targeted boost in temperature and flow control specifically during the cooling phase. By leveraging the mold close signal and the VFD pump functionality, Syncro enhances efficiency during cooling while taking advantage of the natural reheating of the mold cavity for the rest of the cycle. This smart operation significantly reduces cycle times and maximizes productivity. 

The results confirm that the Dynamico system is a powerful, versatile solution for Injection Molding process, offering manufacturers a fast track to higher output and lower operating costs.