Firstly, let's look at how injection moulding tools are typically cleaned. Often, a combination of mechanical and chemical methods are used to remove residual plastic and contaminants. The process begins with the removal of any large pieces of plastic or debris, where technicians use scrapers or brushes to clear away the bulk of the material. After the initial debris is removed, detailed cleaning is often performed using brushes or abrasive blasting, provided the tool’s design and material allow it. In some cases, ultrasonic cleaning baths are used to reach intricate parts of the mould and dislodge stubborn residues.
For residues that are difficult to remove mechanically, specialist cleaning agents or solvents are applied. These chemicals dissolve or loosen any remaining plastic. Finally, some injection moulding machines may run a dedicated cleaning cycle using heated water or steam in combination with detergents.
The main benefits of cleaning moulds and moulding tools thoroughly is to maintain the quality of the moulded parts by preventing contamination between production runs and also to help extend the life of the injection moulding tool itself.
Sounds good, so what’s the catch?
Current cleaning methods for plastic injection moulds and moulding tools present several challenges…
Traditional cleaning processes often require manual labour such as scrubbing or blasting, and can be time-consuming, leading to increased downtime between production runs and reduced manufacturing efficiency.
In addition, some techniques struggle to fully eliminate stubborn plastic residues or degraded build-ups, which can compromise the quality of subsequent moulded parts and lead to tool degradation over time, impacting the tooling lifespan.
Aggressive cleaning agents or abrasive methods can also damage delicate surfaces or intricate components, shortening the mould’s operational life and increasing maintenance costs. Many cleaning chemicals on the market are extremely hazardous, requiring strict handling, proper ventilation, and careful disposal, posing safety risks to operators if not properly managed.
Relying on manual cleaning also introduces variability, as differences in operator technique can result in inconsistent cleaning quality, potentially affecting the moulding process and final product.
Many facilities use ultrasonic cleaning for cleaning small to medium-sized moulds. However, intricate moulds with deep cavities, blind holes, or complex shapes may not be fully exposed to the ultrasonic waves, leading to incomplete cleaning in hard-to-reach areas known as a darkening or shadowing effect. In addition, if contaminants are not fully removed from the solution, they can settle back onto the mould surface, requiring additional rinsing or cleaning steps.
These challenges highlight the need for improved or alternative cleaning strategies that can minimise downtime, ensure consistent cleaning, and protect both the mould and the environment.
BIO-CIRCLE offers a system of specific formulations for the moulding industry that address these common challenges with biodegradable, non-toxic cleaning liquids and effective ultrasonic cleaning processes:
BIO-CIRCLE Master Mould RL is a manual cleaner suitable for cleaning mould inserts quickly, optimally and without damage. Unlike mechanical scrubbing or blasting methods, Master Mould RL gently dissolves dirt and residues without scratching or corroding mould surfaces or requiring excessive agitation. It is VOC-reduced, and much safer to use than solvents, effortlessly and completely removing stubborn contaminants - such as off-gassing - from larger moulds and those with intricate geometries, without residues. Master Mould RL is extremely effective, fast-working and reliable, and achieves consistently good results without depending on the nuances of operator technique.
For ultrasonic baths, Master Mould 100 is a water-based and VOC-free ultrasonic cleaner that has been formulated specifically to remove plastic outgassing, plastic residues, grease, corrosion inhibitors and flash rust on all types of moulds, including those with complex shapes. A feature of Master Mould 100 is its anti-darkening formula, which prevents certain steels from shadowing during cleaning. This makes it a reliable choice for a wide range of materials such as steel, stainless steel, aluminium and non-ferrous metals. Another significant benefit of using Master Mould 100 is that it is VOC-free and therefore does not require specialist handling, storage and disposal, reducing waste chains and risks.
In conclusion, BIO-CIRCLE provides a consistently effective, safe, and time-saving alternative to traditional cleaning methods for plastic injection moulds that addresses the problems associated with using traditional solvents and ultrasonic baths. By reducing downtime, ensuring thorough residue removal, and extending mould life while minimising health and environmental risks, BIO-CIRCLE offers a comprehensive solution to the challenges faced in mould maintenance and cleaning.
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