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Every thermoplastic or thermoset plastic molding machine - on any given molding production line – is limited to a certain number of shots before quality drops and production has to stop for downtime for cleaning.
On average, thermoset and thermoplastic molding machines can do 300 shots before needing to be cleaned. This is because most plastic compounds leave a residue of internal release behind in the cavity after the demoulded part is removed. This builds up and oxidizes causing a terminal deterioration of quality over time.
The rate of deterioration of quality can be significantly decreased by conditioning the surface of your mold. This increases the number of shots between cleaning cycles. Conditioner therefore effectively decreases downtime and increases productivity.
An application of mold conditioner forms a semi-permanent layer on the surface of the mold. This semi-permanent layer seals the microporous metal structure of the mold plates surface. It is also designed to last longer before oxidizing and to function not only as a release but as a mitigating buffer between the internal release of the molding compound and the surface of the mold. Mold Release Sprays, on the other hand, are a temporary layer of a compound designed only to help increase the releasability of the demoulded part.
Another important distinction is that mold release sprays must be manually applied by technicians so they are prone to inconsistent application and even user error. In contrast, mold conditioner is applied mechanically, either by compression or transfer: delivering consistent application: free of human-error.
Mold Release Spray also only last 50 shots before needing another spray which inevitably builds upon previous inconsistencies making the spray ever more uneven over time.
Our pelletized mold conditioner is great for reaching all the nooks and crannies, corners, and edges of more complex or delicate transfer molds. Since they are applied in the same way as the standard pellets of molding compounds they also condition the inner channels and runners of the mold –admittedly this is less of an issue since they are not directly under temperature.
It is also highly accurate: conditioning exactly where the epoxy molding compound with come into contact with mold surface. Our Chemlinq conditioners are especially compatible with epoxy mold compounds because they share the same essential composition, just with much more wax.
The melamine cleans the mold down to the bare metal. It is necessary to have a layer of wax on the surface so that the mold compound will release from the mold.
Once the mold is clean, follow these steps:
Conditioning Wax Sheets are better for covering molds with larger surfaces area as they spread out very far under compression. The sheets come in a variety of different grades: low, medium, and high wax content conditioning sheet for maximum mold surface protection.
Depending on the workability of your molding compound (how easy it demoulds) grades with a higher wax content are better for compounds that tend to cling to the mold cavity more. We also have Wax Conditioning Sheets in low and high viscosity iterations: low viscosity for simple molds and high viscosity for more complex mold cavities.