Fallbeispiel Gartengeräte

A prominent manufacturer of plastic products for the garden and household sector, including garden pots and watering cans, relies on both Injection Molding (IMM) and Blow Molding (BMM) for its production.

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 marketed as the "AI-Assisted" Mold Profit Booster, a technology designed as a direct replacement of any existing TCU (Thermal Control Unit) and improvement of direct cooling from main system.

The key driver for customer's decision was the Dynamico unit's unique ability to:

• Drastically reduce cooling time by delivering ultra-high, stable flow rates—up to five times higher than traditional TCUs—significantly increasing the heat transfer coefficient, while operating completely independently from any centralized system.
• Enable Dynamic Mold Temperature Control (Dual Zone), allowing precise and independent temperature setpoints for each mold half, synchronized with the molding cycle for optimal cooling.
• Ensure a short Return on Investment (ROI) by maximizing productivity with minimal capital expenditure (CAPEX).

Test Conclusions for Plastic Flower Pots

The implementation of the Dynamico unit resulted in an immediate and sustainable increase in productivity for the Injection Molding line.

• The reduction from 39.0 seconds to 34.3 seconds led to a production increase of +13.7%.
• This translates to an annual production boost of approximately +79,100 pieces/year (5 days a week).

The success of Test 1 validates the Dynamico unit's capability as a 'Mold Profit Booster' that can significantly shorten cooling time without requiring any mold modifications.

Test Conclusions for Watering Cans

The Dynamico technology delivered on the Blow Molding application similar exceptional results as shown on IMM for Flower Pots. In short:

• The cycle time was successfully reduced from 21.0 seconds to 18.5 seconds, achieving a production increase of +13.5%.
• This optimization provides an annual output increase of over +144,560 pieces/year for the watering can.

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