Kühlzeit sicher reduzieren

Mai 2026

15,2 % mehr Output durch

sichere Kühlzeitreduktion

Smart Plastify hat mit Moldsonics die fixe Kühlzeit durch zustandsbasierte Entformungsfreigabe ersetzt.

Das Bauteil wird geöffnet, wenn es physikalisch bereit ist — nicht erst, wenn ein Sicherheitspuffer abläuft.

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Kühlzeit

30 s → 14–15 s

Zykluszeit

103,8 s → 88 s

Output

+15,2%

HERAUSFORDERUNG

Kühlzeit ist der Parameter, den niemand mehr anfasst.

Sie wird bei der Abmusterung mit Sicherheitspuffer festgelegt. Jahre später zahlt die Produktion diesen Puffer weiter — weil Reduzieren riskant wirkt: Verzug, Ausschuss, Reklamationen.

LÖSUNG

Moldsonics erkennt, wann das Bauteil wirklich bereit ist.

Der Sensor erkennt den physikalischen Entformungszeitpunkt im Werkzeug. Die Kühlzeit wird zustandsbasiert geregelt; die fixe Zeit bleibt nur als Sicherheitsgrenze bestehen.

Gemessen in der Produktion.

Vorher

– Fixe Kühlzeit: 30 s

– Zykluszeit: 103,8 s

– Versteckter Sicherheitspuffer

– Kühlzeitreduktion = Risiko

Nachher

✓ Zustandsbasierte Kühlzeit: 15 s

✓ Zykluszeit: 88 s

✓ Definiertes Sicherheitsfenster

✓ Kühlzeitreduktion = kontrollierter Output-Gewinn

+15,2 % mehr Output pro Maschine

DIES IST RELEVANT, WENN

Sie vermuten, dass ein versteckter Kühlpuffer vorliegt.

– Die Kühlzeit wurde bei der Probenahme festgelegt und seitdem nicht mehr angepasst.

– Dickwandige Teile begrenzen Ihre Zykluszeit.

– Die Bediener vermeiden es, die Kühlzeit zu verkürzen, da das Risiko von Ausschuss unklar ist.

– Material- oder Prozessschwankungen erfordern Sicherheitsmargen.

Erfahren Sie, wie aus der festen Kühlzeit in der Produktion eine zustandsbasierte Kühlung wurde.

Downloaden Sie den Smart Plastify Use Case mit Messwerten, Aufbau und Ergebnis herunter: Die Zykluszeit wurde von 103,8 s auf 88 s reduziert.

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Moldsonics GmbH
Hafenstraße 47-51
4020 Linz, Austria

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ok aws tranparent ScaleWidthWzgwMF0 Moldsonics Kühlzeit

Visualizing the melting process in injection molding

December 2025

The melting process in the screw is made visible in real time

Moldsonics displays solid and molten areas in the screw channel—right in the middle of the process.

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While developing a new type of heating technology, we were able to analyze the design of our internally heated plasticizing screw in detail for the first time—using process data collected directly from the material flow, without relying on model-based assumptions. Moldsonics provides the data we’ve been waiting for.

Sebastian PÜTTER

Founder and CEO, Smart Plastify GmbH

The challenge

Until now, it has been difficult to observe the melting process inside the screw barrel.
It was not possible to clearly identify solid and molten areas within the screw channel while the process was in progress.

This meant there was no basis for systematically evaluating new heating concepts and plasticization behavior.

Solution

Moldsonics makes the melting process visible in real time.
The sensors detect where solids and molten material are present in the screw channel—right in the middle of the process.

This provides a realistic picture of the plasticization behavior without interrupting the process.

Result

Solid material and melt visible in the screw channel
Plasticization behavior visible in real time
New heating concepts are easier to evaluate
A basis for more targeted litigation

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Moldsonics GmbH
Hafenstraße 47-51
4020 Linz, Austria

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Stabilize the recycled material process

October 2025

Stabilize recycled material processes directly via the ENGEL control system

Moldsonics detects process events within the mold and uses them for cycle switching, cooling time control, and quality data in the CC300.

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The ultrasound-based sensor technology from Moldsonics offers us completely new possibilities for analyzing cyclical processes in our filling processes and thus improving our tools.

Lukas WAGNER

Head of Advanced Simulations, Haidlmair GmbH

The challenge

Recycled materials vary from batch to batch.
This affects filling behavior, solidification, and shrinkage—and makes the process prone to scrap, readjustments, and unnecessary downtime.

Until now, the critical condition in the tool was outside the machine control system.
The machine could see the process. The tool could not.

Solution

Moldsonics brings key molding events directly into the ENGEL CC300.
The flow front, solidification, and shrinkage can be utilized during the cycle—to switch to holding pressure, for adaptive cooling time control, and for the automatic recording of quality metrics.

This way, the process responds not only to machine readings, but also to what is actually happening inside the tool.

Result

Stable process for recycled material
Switching the pressure based on the tool condition
Adaptive cooling time instead of safety time
Quality metrics are saved automatically

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4020 Linz, Austria

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Prevent PUR overflow

October 2025

Detect a PUR overflow before it occurs

Moldsonics erkennt die PUR-Fließfront berührungslos durch den Werkzeugstahl — ohne Sensorabdrücke und mit <5 ms Detektionszeit.

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With Moldsonics sensor technology, it is possible for the first time to detect the PUR flow front without contact - a real benefit for our customers in terms of process reliability and surface quality.

Clemens Kastner

Head of Business Development Automotive & Mobility, ENGEL AUSTRIA GmbH

Screenshot 2025 10 09 154322 Moldsonics Kühlzeit

The challenge

During PUR flooding, the flow front moves very quickly and is difficult to detect reliably. At the same time, no sensor imprints may occur on visible components - a combination that pushes conventional measuring methods to their limits.

Solution

Moldsonics detects the PUR flow front non-contact through the tool steel.
This allows the vent needle to be closed precisely—without coming into contact with the surface.

Result

No sensor fingerprints
< 5 ms Detektionszeit
No uncontrolled PUR leaks at the end of the flow path
Greater process reliability for visible components

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Moldsonics GmbH
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4020 Linz, Austria

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Prevent downtime caused by wear and tear

October 2025

Detect extruder wear before the system shuts down

EREMA uses Moldsonics to measure screw and cylinder wear during operation—providing 24/7 condition data with an accuracy of ±0.05 mm.

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Image: ENGEL Austria

The solution (hardware and software) developed together with Moldsonics enables our customers for the first time to monitor screw and barrel wear conditions continuously and in real time, visualize them in BluPort® and derive maintenance recommendations.

Dr. Michael Aigner

Head of Process Engineering and Product Development , Erema GmbH

The challenge

The screw and cylinder wear out imperceptibly during recycling operations.
If the condition is detected too late, it can lead to unplanned downtime, long lead times for replacement parts, and scrap.

Solution

Moldsonics measures wear non-contact during operation.
The data indicates when the screw or barrel is reaching a critical condition—displayed directly on the HMI and in EREMA BluPort®.

Result

24/7

Status data

± 0.05 (mm)

Measurement accuracy

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Moldsonics GmbH
Hafenstraße 47-51
4020 Linz, Austria

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