Frigel’s Dynamico Mould Temperature Control Transforms Garden Plastics Manufacturer’s Output

A leading garden and household product manufacturer achieved 79,100 additional flower pots and 144,500 extra watering cans per year after upgrading to Frigel’s new Dynamico mould temperature control. Since 2017, Summit Systems has been the exclusive supplier of Frigel products for the UK and Irish plastics market.

A prominent manufacturer of plastic products for the garden and household sector, including garden pots and watering cans, relies on both injection moulding and blow moulding for its production.

Customer’s Needs

The company’s core challenge was directly related to profitability: the mould cooling time, which typically accounts for 40% to 80% of the total cycle time. Optimising this phase is paramount, as a shorter cooling time directly reduces part cost (€/part) and significantly boosts productivity (parts/h).

To achieve this critical productivity increase and enhance overall manufacturing efficiency, the customer opted to implement Frigel’s cutting-edge Dynamico Dual Zone Dynamic Mould Temperature Control technology, choosing the Dynamico DYD 260 HP VF unit (Dual Zone with High Pressure Pumps).

The Dynamico line is marketed as the “AI-Assisted” Mould Profit Booster, a technology designed as a direct replacement of any existing TCU (Thermal Control Unit) and improvement of direct cooling from the main system.

The key driver for customers’ decision was the Dynamico unit’s unique ability to:

• Drastically reduce cooling time by delivering ultra-high, stable flow rates—up to five times higher than traditional TCUs—significantly increasing the heat transfer coefficient, while operating completely independently from any centralised system.
• Enable Dynamic Mould Temperature Control (Dual Zone), allowing precise and independent temperature setpoints for each mould half, synchronised with the moulding cycle for optimal cooling.
• Ensure a short Return on Investment (ROI) by maximising productivity with minimal capital expenditure (CAPEX).

“Increased production of over 79,000 additional garden pots per year thanks to the replacement of current TCUs with Dynamico units.”

Test Conclusions for Plastic Flower Pots

The implementation of the Dynamico unit resulted in an immediate and sustainable increase in productivity for the injection moulding line.

• The reduction from 39.0 seconds to 34.3 seconds led to a production increase of +13.7%.
• This translates to an annual production boost of approximately +79,100 pieces/year (5 days a week).

The success of Test 1 validates the Dynamico unit’s capability as a ‘Mould Profit Booster’ that can significantly shorten cooling time without requiring any mould modifications.

Test Conclusions for Watering Cans

The Dynamico technology delivered on the Blow Moulding application, similar to the exceptional results shown on IMM for Flower Pots. In short:

• The cycle time was successfully reduced from 21.0 seconds to 18.5 seconds, achieving a production increase of +13.5%.
• This optimisation provides an annual output increase of over +144,560 pieces/year for the watering can.

The results confirm that the Dynamico system is a powerful, versatile solution for both injection moulding and blow moulding processes, offering manufacturers a fast track to higher output and lower operating costs.

“Achieved an annual output increase of 144,500 Watering Cans, thanks to Dynamico technology, cutting the Cooling Cycle Time.”

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