Injection Molding Machine Cooling Project: KEJU Counter Flow Closed Circuit Cooling Tower To Solve High-Load Injection Molding Heat Dissipation
May 15, 2026
A large home appliance casing injection molding manufacturer has multiple large-tonnage injection molding machines (over 1000 tons) densely packed in its workshop. Due to the short injection molding cycle and high mold closing pressure of home appliance casings, the equipment generates enormous heat under prolonged high-load operation. The customer's existing traditional cross-flow open cooling tower is insufficient for heat dissipation during the hot summer months, resulting in severe water drift and a slippery environment in the workshop. It also frequently triggers injection molding machine alarms due to excessively high cooling water temperatures, severely restricting the overall production capacity of the workshop.
Project Overview
● Industry: Large-scale injection molding / Home appliance casing manufacturing
● Equipment Used: Large-tonnage injection molding machines, hydraulic systems, and mold cooling
● Core Product: KBL series counter-flow closed-circuit cooling tower
● Key Challenges: Insufficient heat dissipation under high load conditions; traditional equipment is bulky and suffers from severe water drift; cooling water temperature fluctuations impacting production capacity.
Challenges and Tasks
To ensure timely delivery of peak season orders and improve the workshop environment, the client made specific requests to KEJU Machinery regarding a cooling system upgrade:
1. Coping with high-load heat dissipation: The new system must possess extremely strong heat exchange capabilities to ensure sufficient cooling for large-tonnage injection molding machines even in extreme summer temperatures of 40°C.
2. Improving space utilization: Due to limited installation space in the workshop, the cooling equipment must be compact, have a small footprint, and facilitate easy pipe connections.
3. Eliminating water drift and pollution: Completely resolve the workshop water accumulation and environmental pollution problems caused by open tower water drift, while preventing impurities from entering the injection molding machine's hydraulic system, ensuring long-term stable equipment operation.
KEJU COOLING Solutions
For clients with specific operating conditions requiring "high load, limited space, and zero pollution," KEJU COOLING's technical team, after precise heat load calculations, tailored the KBL series counter-flow closed-circuit cooling tower solution:
● High-efficiency Counter-flow Heat Exchange Design: This series of towers employs advanced counter-flow heat exchange technology. Cooling water flows within coils, while spray water and air exchange heat in opposite directions within the tower. Compared to traditional designs, the counter-flow structure significantly increases the temperature difference and contact time for heat exchange, improving heat exchange efficiency by 15%-20%, perfectly handling the instantaneous high-temperature shocks during high-load operation of injection molding machines.
● Compact Structure Saves Space: The counter-flow closed-circuit cooling tower features a vertical, compact design, maximizing heat exchange area per unit space. For the same cooling capacity, it occupies approximately 30% less space than traditional crossflow towers, perfectly suited for narrow installation areas. It also supports parallel operation of multiple units, facilitating future capacity expansion.
● Fully Enclosed Circulation Eliminates Pollution: The system utilizes a fully enclosed soft water circulation system. The internal cooling water flows within sealed copper or stainless steel coils, completely isolating it from external dust, fluff, and other impurities. This not only eliminates the water drift phenomenon common in traditional open-circuit towers, keeping the workshop floor dry and clean, but also effectively prevents scaling and blockage in the injection molding machine's hydraulic lines and mold flow channels.
● Intelligent Variable Frequency Energy-Saving Control: Equipped with a self-developed intelligent PLC control cabinet from Keju, it monitors the outlet water temperature in real time. When the injection molding machine is in standby or low load mode, the system automatically reduces the frequency of the fan and water pump; when multiple injection molding machines are working at full load at the same time, the system quickly increases the power, and while ensuring constant temperature (temperature control accuracy ±1℃), it achieves a reduction of about 25% in overall energy consumption.
Project Results: 40% Capacity Increase & Cost Reduction
After one year of stable operation following delivery, the KEJU counter-flow closed-loop cooling tower system has brought immediate production benefits to the customer:
● Significantly Increased Capacity: Thanks to the powerful heat dissipation capabilities of the counter-flow design, even in the sweltering summer heat, the cooling water outlet temperature remains stable below 32°C. Injection molding machine cooling time has been reduced by approximately 15%, and continuous operating time has increased from 12 hours/day to 24 hours/day, resulting in an overall capacity increase of 40%.
● Significantly Reduced Maintenance Costs: The fully enclosed circulation system completely eliminates scaling issues, extending equipment maintenance intervals from once a month to once a quarter. Simultaneously, by eliminating drift and water pollution, overall operating and maintenance costs have been reduced by 25%.
● A qualitative Leap In The Workshop Environment: The workshop is now free of slippery surfaces and water accumulation caused by cooling tower drift, and equipment operating noise is below 65 decibels, significantly improving the working environment for employees and meeting the environmental protection requirements of a modern factory.
Real Customer Feedback
KEJU's counter-flow closed-circuit cooling tower not only solved our problem of limited space, but its powerful heat dissipation capacity has also enabled us to reach a new level of production capacity, truly achieving high efficiency and peace of mind!
Is your injection molding workshop facing challenges such as limited space or insufficient heat dissipation in summer? Contact KEJU engineers immediately for free counter-flow closed-circuit cooling tower selection solutions and site planning advice.
