Interview: Brain Unfreeze

Is Artificial Intelligence redefining process cooling in extrusion and injection molding? 💡

Until recently, optimizing cycle times meant making costly modifications to mold designs or investing in high-tonnage presses. Today, the answer lies in dynamic thermal efficiency.

In the latest special issue of Canadian Plastics, Mario Coletti, Area Sales Manager at Frigel North America Inc., highlighted this historic transformation:

Riding this wave of innovation, the manufacturing ecosystem is showing extraordinary interest and success in our revolutionary Dynamico system, with strong adoption by both OEMs and processors.

Thanks to AI-assisted dynamic temperature control, Dynamico integrates seamlessly into existing production lines without requiring any modifications to the mold. It drastically reduces cooling times, cuts energy costs per part, and boosts overall productivity by up to 50%.

Process cooling is no longer a passive variable—it is a primary driver of operational profitability.

The Future of Process Cooling in Plastics Manufacturing: 

The Era of Advanced Controls and AI In the plastics processing industry, the stability and repeatability of thermal control directly dictate the success of the entire production run. Consistent cooling not only ensures optimized cycle times, but also protects mold tooling and prevents structural or cosmetic defects in finished components. 

Today, the intersection of Industry 4.0 and Artificial Intelligence is ushering in a new era of efficiency, transforming industrial chillers from passive ancillary equipment into highly intelligent, interconnected systems.

The Industry 4.0 Evolution: Turning Data into Actionable Insights 

Over the last fifteen years, digitalization has radically transformed plant management. Modern control systems can now track complex KPIs in real time, including: 

• Energy consumption and refrigerant pressures.
• Vibration levels and component health for predictive maintenance. 
• Ambient dewpoint monitoring to prevent mold sweating. 

A Paradigm Shift with the DYNAMICO™ System

While much of the industry still views water temperature as a static set-point, Frigel has introduced a true market paradigm shift with **Dynamico**, the innovative, AI-assisted *"Mold Profit Booster."

Key Pillars of Dynamico Technology::

• Zero Structural Modifications: Seamlessly replaces traditional temperature control units (TCUs) with an immediate, "plug-and-play" integration on existing production lines.
• AI Algorithms & Dynamico Wizard: Through an intuitive user interface, proprietary software analyzes process data entered by the operator alongside real-time press signals (mold open/close), guiding technicians step-by-step to achieve the shortest possible cooling time without compromising part quality.
• High-Turbulence Booster Pumps: The system independently regulates flow rates across both mold halves, delivering ultra-high flow rates (up to 500% higher than conventional TCUs) to maximize the heat transfer coefficient.

Proven Results: Guaranteed Productivity and Sustainability Feedback from customers and OEM partners confirms the extraordinary success of Dynamico technology across strategic sectors such as automotive, medical, packaging, and technical molding. Dynamic temperature optimization delivers: 

1. A 20% to 50% increase in productivity, due to a drastic reduction in cycle times. 
2. Up to a 15% reduction in energy and operational costs** per manufactured part. 
3. A projected Return on Investment (ROI) achieved within just a few months. Frigel continues to drive global innovation in process cooling, proving that high-performance engineering and environmental sustainability can—and must—go hand in hand.