Analysis of air-cooled chillers used in the injection molding industry
Professional application in plastics and injection molding industry
1. Injection molding temperature control
During the injection molding production process, precise control of mold temperature directly affects product quality and production efficiency. Kangsi air-cooled chillers provide a full range of cooling solutions for the injection molding industry:
1.1 Small precision injection molding
Applicable to the production of precision plastic parts such as electronic connectors and medical devices, requiring:
Quick response to mold temperature changes
Eliminate product deformation caused by uneven cooling
Maintain temperature stability within ±0.5℃
1.2 Injection molding of large thick-walled products
Characteristics of thick-walled products such as automotive parts and home appliance housings:
Provide large-flow cooling water circulation (up to 120m³/h)
Secondary cooling system prevents water temperature from rising
High-pressure design ensures that cooling water flows fully through complex mold waterways
1.3 High-speed thin-wall injection molding
Meet the high-speed production needs of packaging containers, disposable tableware, etc.:
Ultra-fast cooling capacity shortens molding cycle
Multi-pump parallel design ensures continuous and stable cooling
Specially designed buffer water tank reduces pressure fluctuations
2. Extrusion molding production line
Provides for the extrusion production of plastic pipes, plates, profiles, etc.:
Partitioned cooling control of screws and barrels
Reliability of long-term continuous operation
Adapt to the cooling needs of different plastic raw materials (PP, PE, PVC, etc.)
3. Blow molding applications
In the blow molding production of PET bottles, plastic containers, etc.:
Precisely control the temperature distribution of the parison
Rapid cooling ensures the transparency of the bottle wall
Energy-saving design reduces production costs
4. Special plastic processing technology
Reaction injection molding (RIM): Control the reaction temperature to prevent premature solidification
Gas-assisted injection molding: Precisely control the cooling of the gas channel
Multi-component injection molding: Independently control the cooling rate of different materials
Case Study: For a major automotive components wholesaler, we implemented a customized solution featuring 20×80HP air-cooled units with advanced predictive maintenance capabilities. The system achieved uninterrupted 365-day continuous operation with less than 0.5% downtime, while reducing energy consumption by 28% compared to their previous installation.
Core Technical Advantages of Air-Cooled Chillers
As a professional industrial temperature control equipment manufacturer with over two decades of industry experience, KANSA Refrigeration has pioneered the development of advanced air-cooled chiller systems that set new benchmarks in energy efficiency and operational reliability. Our self-developed air-cooled chillers incorporate cutting-edge heat exchange technologies and innovative system architectures that deliver 30% more compact installation footprints compared to conventional water-cooled models, while completely eliminating the need for additional cooling towers and complex piping infrastructures.
Our state-of-the-art factory complex spans over 8,000 square meters in Shanghai province, featuring fully automated sheet metal processing lines with 0.1mm precision tolerances, robotic welding stations, and comprehensive intelligent testing equipment. Every chiller unit undergoes rigorous quality control procedures to ensure full compliance with ISO9001 quality management system certification, as well as meeting stringent international standards including CE, UL, and ASHRAE performance requirements.
Advanced Product Features:
- Superior Energy Efficiency:Utilizing our proprietary hybrid scroll/screw compressor technology paired with high-efficiency EC fan arrays, our chillers achieve industry-leading IPLV (Integrated Part Load Value) ratings exceeding 4.5, delivering substantial energy savings throughout the entire operating range.
- Intelligent Control Ecosystem:The 7-inch full-color touchscreen HMI integrates advanced IoT connectivity modules, enabling real-time remote monitoring, predictive maintenance alerts, and seamless integration with building management systems through Modbus, BACnet, and LonWorks protocols.
- Exceptional Operational Stability:Engineered for reliable performance across extreme ambient conditions (-15℃ to 45℃), our chillers incorporate multiple redundant protection systems including high/low pressure safeguards, phase sequence monitoring, and anti-freeze protection circuits.
- Modular Scalability:With single unit capacities ranging from 5-200RT, our modular design philosophy allows for flexible multi-unit parallel configurations to meet custom capacity requirements, featuring intelligent load balancing algorithms that optimize energy consumption.
- Environmentally Conscious Design:Available with R410A, R32, or future-proof R290 natural refrigerant options, our chillers achieve remarkably low noise levels down to 65dB(A) through advanced acoustic engineering and vibration isolation technologies.
KANSA Refrigeration’s Comprehensive Competitive Advantages
As an industry-leading manufacturer with 25 years of continuous innovation, we have developed three interconnected advantage systems that differentiate our solutions in global markets:
1. Cutting-Edge Research and Development Capabilities
Our 5,000 square meter R&D center houses advanced testing facilities including:
Full-scale enthalpy difference laboratories with climate simulation capabilities
Computational Fluid Dynamics (CFD) simulation workstations
Materials testing laboratory for corrosion resistance evaluation
Acoustic measurement chambers for noise optimization
In partnership with Tsinghua University’s Department of Thermal Engineering, we maintain a joint research center focused on next-generation heat transfer technologies. Our annual R&D investment exceeds 8% of revenue, resulting in 67 patented technologies including 12 invention patents in advanced refrigeration cycles and heat exchanger designs.
2. World-Class Manufacturing Infrastructure
Our vertically integrated production facilities feature:
Industry 4.0 automated production lines with real-time quality monitoring
Robotic welding cells achieving 0.1mm repeatability
Fully automated refrigerant charging and testing stations
40-ton overhead cranes for large system assembly
On-site metal fabrication including laser cutting and CNC bending
The manufacturing execution system (MES) tracks every component through the entire production process, ensuring complete traceability. Our flexible production system accommodates everything from single custom units to large wholesale orders with lead times 30% shorter than industry averages.
3. Global Service and Support Network
Our customer-focused service infrastructure includes:
Regional technical support centers in Asia, Europe, and North America
24/7 multilingual technical assistance hotlines
Augmented reality (AR) remote support capabilities
Localized spare parts inventories at 5 global logistics hubs
Certified technician training programs at our headquarters
The proactive monitoring platform analyzes operational data from connected chillers worldwide, identifying potential issues before they affect performance. Our average emergency response time is under 24 hours for critical applications.
Customer Value Creation Process
Our systematic approach ensures optimal solutions for every application:
1. Comprehensive Needs Assessment
On-site thermal load evaluation using infrared thermography
Process cooling requirement analysis
Utility infrastructure review
Future expansion planning
2. Engineered Solution Development
CFD modeling for system optimization
Energy efficiency simulations
Control strategy development
3D plant layout integration
3. Precision Manufacturing
Custom fabrication to exact specifications
Rigorous component testing
Complete factory acceptance testing
Detailed documentation packages
4. Professional Installation & Commissioning
Certified installation teams
Full system performance validation
Operator training programs
Initial maintenance planning
5. Continuous Performance Optimization
Remote monitoring services
Periodic efficiency audits
Preventive maintenance programs
Technology upgrade options
Complete Product Portfolio
Standard Series Solutions
Compact Units (5-20HP): Ideal for small-scale processes (-5℃~30℃ range)
Mid-Range Systems (25-100HP): Workhorse models for most industrial applications (-15℃~35℃)
Large Capacity Units (120-200HP): High-efficiency solutions for major facilities (-25℃~45℃)
Special Application Series
Ultra-Low Temperature: Cascade systems down to -40℃ for specialty processes
Hazardous Area Certified: Complete ATEX-compliant explosion-proof range
Variable Frequency Drive: IP65-rated outdoor models with wide turndown ratios
Reversible Heat Pumps: Simultaneous heating/cooling capability for energy recovery
Environmental Stewardship Commitments
- Sustainable Manufacturing
92% material recycling rate across all production processes
Solar panel arrays providing 30% of factory power needs
Zero landfill waste policy
- Eco-Conscious Products
Full transition to R290 natural refrigerant by 2025
Energy recovery options for waste heat utilization
Lead-free construction materials
- Circular Economy Initiatives
Chiller refurbishment and modernization programs
Core component reuse system
End-of-life equipment recycling services
- Carbon Footprint Reduction
Logistics optimization reducing transportation emissions
Energy efficiency consulting services
Carbon offset partnership programs
Why Choose KANSA as Your Cooling Solutions Provider?
Shanghai KANSA Refrigeration Equipment Co., Ltd. is an innovator in the industry, with strong R&D capabilities, advanced equipment, and professional products and solutions. Over the years, Kangsai has met customer needs with its unremitting pursuit of industry-leading technology and its ability to foresee industry trends, while maintaining the Kangsai brand’s characteristics of sincerity, rigor, and high quality. Our company uses advanced production and inspection equipment, and implements strict control over every detail from raw materials to finished products to ensure the performance and quality of each product.
Manufacturer Direct Pricing: As a factory-direct supplier, we offer competitive wholesale rates without middleman markups
Application Expertise: Our engineers understand your industry’s unique cooling challenges
Rapid Prototyping: Ability to develop and test custom configurations quickly
Scalable Production: From small batches to large volume orders
Comprehensive Support: From initial consultation through installation and maintenance
For OEM partners and system integrators, KANSA offers white-label custom solutions with flexible branding options. Our engineering team can collaborate on fully integrated thermal management systems tailored to your specific equipment requirements.
KANSA Refrigeration Company Strength Display
Company Profile
Shanghai Kangsai Refrigeration Equipment Co., Ltd. was established in 2002. It is a national high-tech enterprise specializing in the research and development, production and sales of industrial refrigeration equipment. As a leading manufacturer and supplier in the industry, we have two modern production bases:
Two major production bases in Shanghai and Shenzhen
- Shanghai Factory
The Shanghai Factory is located in Pudong New Area, Shanghai. It has a modern factory building of 8,000 square meters and related supporting facilities. The company has a large number of experienced and well-trained managers and technical workers, as well as experienced technical experts. In terms of manufacturing equipment and product testing and detection methods, they include: fully automatic sheet metal flexible production line, AMADA digital bending machine, fully automatic loading and unloading laser cutting machine, a full set of fin heat exchanger production line, high vacuum cold well degreasing furnace, fully automatic water storage tank production line, fully automatic fluorine pipeline production line, product online testing platform and electrical safety performance device certified by national authoritative departments, etc., and follow Kangsai’s quality control system to achieve high-quality goals and manufacture high-quality products.
- Shenzhen Factory
The Shenzhen Factory is located in Bao’an District, Shenzhen, with a factory area of 4,800 square meters and a beautiful office environment. All technology and production management are synchronized with Shanghai Kangsai. The company has advanced sheet metal production lines, AMADA digital bending machines, high-speed laser cutting machines, and a full set of fin production lines. Fully automatic fluorine pipeline production equipment.
Global Applications and Case Studies
KANSA precision chillers have been successfully deployed in:
University research laboratories conducting nanotechnology studies
Semiconductor fabrication facilities producing advanced chips
Aerospace component manufacturers requiring micron-level machining accuracy
Medical device companies developing next-generation imaging systems
National research institutions with demanding experimental requirements
Our portfolio includes compact 1kW chillers for benchtop instruments up to 500kW centralized cooling systems for industrial processes. All systems share the same commitment to precision, reliability, and energy efficiency.
Partner with KANSA for Your Cooling Needs
As a fully integrated manufacturer, KANSA Refrigeration offers the industry’s most comprehensive range of temperature control solutions from compact 3.5kW chillers to 2000kW centralized systems. Our expertise covers:
OEM and Private Label Services: Complete white-label solutions with your branding
Application-Specific Custom Designs: Engineering support for unique requirements
Volume Wholesale Programs: Attractive pricing for large orders and multi-site deployments
Turnkey Project Solutions: Single-source responsibility for complete cooling systems
Contact KANSA for Your Custom Cooling Solution
As a professional manufacturer with strong factory capabilities, KANSA Refrigeration stands ready to provide the perfect temperature control solution for your application. Whether you need standard models from our catalog or fully custom-designed systems, our team will deliver optimal performance and reliability.
We welcome wholesale inquiries and long-term partnership opportunities. Our global distribution network ensures prompt delivery and local support wherever your operations are located.
Discover the KANSA difference in precision cooling technology. Contact our technical sales team today to discuss your requirements and receive a tailored proposal for your specific application needs.