Intelligent Process Cooling

High Performance Cooling for Your ProcessMicro Turbo

Bill Ruba, Vice President Manufacturing of Central Can Company, USA, on Frigel Microgel®

“Frigel’s system has allowed us to improve our cycle times, greatly improving our efficiency, opening up a month’s worth of capacity which has greatly effected our bottom line. It has reduced overtime costs and dramatically reduced our labor costs and machine costs associated with running this product. ”

Boost Your Productivity!

Increase Your Efficiency!

To Increase Productivity, Decrease Cooling Time

Factors Controlling Cycle Time

Water TemperatureDedicated Cooling

Single or Dual Zones0 to 90 °C (32 to 194 °F)

Precise Control Dedicated ControlPrecision ± 0.1 °C (0.2 °F)

Water FlowDedicated Pumping

∆T =2 °C (4 °F) Mono∆T =1 °C (2 °F) DuoHigh and ConstantFlow and Pressure

Solutions

MICROGEL® / TURBOGEL® BETTER COOLING EFFICIENCY. SHORTER CYCLE TIME.

Injection Molding: Impact of Cooling Time on Cycle Timefrom 40% of cycle time (high speed packaging) up to 90% of cycle time (engineering resins)

MACHINE SIDE CHILLER+TCU FROM 0 TO 90 °C (FROM 32 TO 194 °F)

Cycle Time

Production Quantity

Scrap Production Quality

Microgel – RCM-RCD – Flexible and Precise

PRECISE COOLING WATER TEMPERATUREIt supplies the temperature required (± 0.1°C /± 0.2 °F) by each process without thermal losses, delivering the chilled water close to the point of use,with complete independence from other processes.

CONSTANT HIGH FLOW RATE THROUGH THE MOLDIt supplies a constant high flow rate and pressure without pressure drops along the main pipelines, producing the pumping energy close to the point of use. Pumping energy consumption is 30 to 40% less than in Central Systems.

The Microgel® RCM-RCD water cooled chillers/TCUs are conceived for the control of process water of a single user. It is controlled by a microprocessor and fitted with a particular proportional control regulation valve which allows the set temperature to be kept perfectly precise and constant.The Microgel® units are designed to guarantee, adjust and constantly monitor a very high water flow to the mold. A turbulent flow means better heat exchange efficiency and a much more uniform temperature of the mold. This results in greatly reduced cooling time and much better part quality.An integrated automatic free-cooling system allows high energy savings to be achieved by exploiting the ambient temperature for cooling when possible.

Two versions available:

RCM - SINGLE ZONE - Offers the possibility of operating at constant temperature, flow and pressure; operating temperatures of minimum 0 °C (32 °F) and maximum + 90 °C (194 °F).

RCD - DOUBLE ZONE – Harnesses the power of two Microgel® single zone RCM series machines in a single unit, saving a lot of space next to your process machine. This version is capable of automatically dividing the cooling capacity according to the thermal load of each zone in a completely independent way.

RCDDouble Zone Water Cooled Process ChillerFlow rate up to 76 m3/h (334 gallons/minute)Available with high pressure process pumps, too.

Micro

MICROGEL® / TURBOGEL® HIGHER FLOW RATE. BETTER QUALITY.

MACHINE SIDE TCU UP TO 90 °C (194 °F)

CENTRALIZED COOLING VS. Low and Unstable FlowHigh Delta TFluctuating Temperature

COOLING WITH DEDICATED PROCESS CHILLERHigh and Constant FlowLow Delta TPrecise Temperature

Turbogel – RBM-RBD – Boost Your Mold

High Pumping Energy at the Point of UseComplete RepeatabilityHighest ProductivityLowest Energy Losses

UNIQUE FEATURESPUMPS - High Performance (flow/pressure)COOLING VALVES - Modulating proportional servo-valvesSENSORS - 2 pressure & 3 temperature sensorsCONTROL - Powerful microprocessor controlELECTRIC BOARD - w/ circuit breakersRUST FREE CIRCUITS

HIGH PERFORMANCEPerfect control of Process Cooling, thanks to:• Capacity to keep a very high and constant

flow rate of water to the process;• Ability to minimize the difference in temperature

between the cooling water from the central system and the process water delivered to the mold.

High Cooling Efficiency - Turbulent Flow - High flow ratesHigh Heating Capacity - up to 48 kWHigh Reliability - Microprocessor sophisticated alarm system

This line of Temperature Controllers is characterized by a very high flow rate, very high cooling capacity and excellent product precision at minimum energy costs. The hydraulic performance is the same as the rest of the Microgel® family.

Two versions available:RBM - SINGLE ZONE - Offers the possibility of operating at constant temperature, flow and pressure; a real “booster” of the water circulating in the mold. Set point up to 90 °C (194 °F).RBD - DOUBLE ZONE – Encloses the potential of two Turbogel® single zone RBM series machines in a single unit, saving a lot of space next to your process machine. This version is capable of automatically keeping two zones of the mold at two completely independent temperatures, flows and pressures.

Flow rate up to 240 m3/h (over 1,000 gallons/minute)Available with high pressure process pumps, too.

Turbo

TCU FOR EVERY APPLICATION

Microgel® and Turbogel® are available for customized applications. Specific models have been designed for Extrusion and PET Preform Molding.

Microgel – RCX – Revolution in Cooling of Extruder

The Microgel® RCX units are compact, water-cooledchillers, designed for cooling and/or temperature control of atmospheric pressure tanks in different industrial applications, mainly for plastic material extrusion.

Microgel – RCP – High Performance in PET Preforms

The Microgel® RCP units are compact, water-cooled chillers, with high cooling capacity, that, thanks to their ability to supply high pressure and high flow rate to the process, are perfectly suited to cooling for injection molding of PET preforms and in general for packaging. With a shell-and-tube condenser, they can be utilized in existing plants with open type Cooling Towers.

Microgel – RAM-RAD – Plug-and-Cool

The Microgel® RAM and RAD units are compact, air-cooled chillers, with the same features as the RCM-RCD units. They are designed as a stand-alone machines: no need for connections to main water systems.Two versions available:

RAM - SINGLE ZONE RAD - DOUBLE ZONE

CENTRAL SYSTEMS MACHINE SIDE TCU

ProductivityLack of flexibility in temperature control. Variable water flow to molds, highly affected by the other users.Higher cooling cycle time due to high and variable delta T on molds.No possibility of communication with processing machines.

Running costsLow reliability and high investment cost for a stand-by unit.High water pressure drops across the main water pipelines. Need to reheat water for molds requiring a higher temperature than the one provided by the central chiller.Need to keep the central chiller temperature set-point at the lowest temperature required by all molds.High refrigerant gas emission (high environmental impact) in case of leakage.

InstallationHigh costs for pipe insulation.Complicated and costly initial installation for centralized pump-tank groups.Complicated and costly expansions.

DISADVANTAGES ADVANTAGES

vs.

ProductivityPossibility of searching and repeating the optimum cooling conditions for each mold. Complete independence of each setting. Precise automatic control of the mold temperature. Cooling conditions (temperature AND flow) permanently stable and under control for each mold. High cooling efficiency with low delta T of the process fluid through the mold, producing lower cycle times.A much higher quality of molded parts. Less scrap. Communication interfaces available with process machines.

Running costsTotal reliability, easy to replace with a spare unit in case of failure, minimum production downtime. Reduced pressure drops across the main water pipelines.High and constant flow often allows higher fluid temperature, reducing the risk of mold sweating and reducing energy consumption.Free-cooling opportunities as a standard feature.Little refrigerant gas emissions in case of leakage (minimum environmental impact).

InstallationSimple, quick and inexpensive installation. No need for intricate central pumping groups.No need for main pipe insulation.Modular concept is easy to expand.

MICROGEL® / TURBOGEL® MAXIMUM ENERGY SAVINGS.

Ambient T <= 10 °C / 50 °F

Water T in main piping: 15 °C (59 °F)

PROCESS COOLING:

Process Set Point 15 °C (59 °F)

Microgel Compressor OFF

Process Set Point 10 °C (50 °F)

Microgel Compressor ON

Process Set Points 20 and 30 °C (68 and 86 °F)

Microgel Compressor OFF

Process Set Point 40 °C (104 °F) Turbogel

MAIN FEATURES:

- Sophisticated control by micro-processor

- Search and repetition of best cooling conditions

- Dedicated Cooling and Pumping

- High Water Flow Rate to the Mould

- Reading and Setting of flow rate and pressure

- Automatic Loading and Draining of process water

- Warnings, in case of change of flow rate value

- Low energy consumption

Extremely reliable!

More uptime for your

whole plant!

Modular concept easy to expand!

- Minimum pressure drops

- Minimum environmental impact

- Simple and economical installation

- Quick start-up

- Super compact – portable

- Free-cooling valves included in all models

- Communication interface available for main process

machines

- Definitive solution for main cooling problems:

such as condensation, appearance of the piece,

consistency of dimensions, etc.

Intelligent Process Coolingwww.frigel.com

Ask for a Free Cycle Time Study of any of your Molds!

Head Quarters: Frigel Firenze SpAVia Pisana, 31650018 Scandicci (FI, Italia)Tel +39.055.7220920Fax +39.055.7311271E-mail: sales@frigel.it

Frigel - North Italy branchVia Cesare Battisti, 3725017 Lonato (BS, Italia)Tel +39.030.9130461Fax +39.030.5100360E-mail: frigelbs@frigel.it

Frigel North America Inc.150 Prairie Lake Rd, Unit AEast Dundee, IL. 60118 USATel +1 (847) 540-0160Fax +1 (847) 540-0161E-mail: info@frigel.com

Frigel Asia-PacificFirst Floor, Building no. 9Zhangcha Administrative ZoneChanheng District - 528000 Foshan, GuangdongP.R. of ChinaTel-Fax +86 (757) 82516010Mob +86 (150) 02198203Email: frigel.asia.pacific@frigel.it