Hot runner system represent the

most extensive technological

development from conventional
runner system to a system ready to
be installed.
Large moulding such as automotive
dash boards , bumpers,computer
housing etc. could be produced in
practice without multiple melt
supply.
Nozzles upto 8mm length and
runners upto 1800mm are applied
in such large moulds.
All materials can be moulded in
hot runners,even reinforced
plastics and structural foam.Certain
limitation are applicable for
thermally sensitive plastics and in
particular flame resistant material.
 Saving in material for runner cost
for regrind
Shorter cycles,time for demoulding
runner system is omitted, cooling
time is not determined by slow
freezing,no runner break off.
 Smaller machines are adequate,
runner system does not create
reactive forces,short size is reduced
by volume for runners or larger shot
size is available for filling larger
number of cavities,shorter opening
stroke than for three plate moulds.
 mould making has recourse to mould
standards.
Omission of demoulding the
runner system permits simpler
automation of processing.
Heated runners allow the
realization of long flow paths.
Option to place the gate at an
optimum location.
Diameter of runners can be kept
large resulting in less pressure
loss
Longer holding pressure is made
possible
Balancing of the runner system can
be done by temperature control or
mechanically
Use of shut-off nozzles may avoid
formation of knit lines
More rejects at least during start up
More work in mould design
Higher mould costs for installation
More susceptible to trouble such as
leak or failure of heating elements.
Hazard of thermal degradation of
sensitive materials because of long
flow path and high shear velocity
No pressure control from gates
 HOT RUNNER SYSTEMS
The sprueless moulding principles have been
well known since the ‘50s, even though their
use on a vast scale only dates back to the
beginning of the ‘70s. Hot runner injection
moulds are gaining wide acceptance as they
give cheaper production as a result of shorter
cycle times and scrap reduction. The advantages
are that they have no sprues, no runners and that
the machine plasticising capacity is used almost
completely
 HOT RUNNER SYSTEMS
In fact, the molten material remains under
optimum viscosity conditions while it is being
transferred from the feed bush through the
runners up to the mould cavities. In the feed
runners, the mass of molten material should be
kept constantly hot, that is in a fluid state, ready
for the new shot. On the conceptual standpoint,
hot runners are not thermally influenced by
moulding breaks and across their cross sections
temperature is always constant
HOT RUNNER SYSTEMS
Hot runner cross sections may be very small,
thereby ensuring constant filling stages over
time. Runners into which resin flows must be
designed in such a way to have special
characteristics
 HOT RUNNER SYSTEMS
- the size must be such not to create
high shear speeds which would result
in pressure drops and overheating;
- cross sections must not be too small
to avoid material degradation and
problems in colour change;
- runners are to be balanced and
sized in such a manner not to cause
problems when filling the impressions.
HOT RUNNER SYSTEMS
 HOT RUNNER SYSTEMS
Furthermore, a number of practical
and easy-to-service systems are used
to get even temperature. Types most
broadly used are: heater bands,
cartridge bands, spiral bands, low or
high voltage bands, heat tubes.
Another critical design element is the
gate, both for the nozzle construction
and quality of moulded part.
HOT RUNNER SYSTEMS
Gates are divided into four types:
- circular gate;
- ring gate;
- side (edge) gate;
- valve gate;
.
 HOT RUNNER SYSTEMS
- Circular shape nozzles, used for non critical
materials and applications, are made from high
conductivity metals. Thus, they are heated up by
simple contact with the distributor; in addition, at
the border they are insulated by means of the same
resin to inject which flows inside a hollow space
located between the bush and mould. In order to
maintain even thermal profile along the nozzle, the
nozzles must not be too long, in particular L = 2*D.
The nozzle can sometimes be equipped with a hot
tip .
HOT RUNNER SYSTEMS
 HOT RUNNER SYSTEMS
- Circular shape nozzles, used for non critical
materials and applications, are made from
high conductivity metals. Thus, they are
heated up by simple contact with the
distributor; in addition, at the border they
are insulated by means of the same resin to
inject which flows inside a hollow space
located between the bush and mould. In
order to maintain even thermal profile along
the nozzle, the nozzles must not be too long,
in particular L = 2*D. The nozzle can
sometimes be equipped with a hot tip.
 HOT RUNNER SYSTEMS
Ring type nozzles are similar to circular ones. The
only difference is that ring types have a central tip
which prevents the nozzle from cooling prematurely.
The tip may be constructed in a variety of shapes and
materials. High thermal conductivity materials can be
used (Be-Cu alloys). Sometimes, tips are to be
subject to nickel plating processes for major
protection as certain polymers (e.g.: PA) react with
these alloys; in some other cases, when abrasive
resins are to be processed, hard metal is used
HOT RUNNER SYSTEMS
 HOT RUNNER SYSTEMS
SIDE (EDGE) GATE
Gates with side entrance are more critical that
previous gate styles. They allow side gating of parts
and are used for pieces which must be injected at
the centre of a hole with multiple injections or for
parts which do not accept capillary gate. The
insulating material at the bottom of the nozzle is
very near to the part surface in the injection area.
The width of the gate is to be less than part
thickness. Therefore hot resin must be brought very
close to the part (0.5-1 mm), but this makes the
local, mechanical resistance of the mould quite
critical and the part itself is overheated.
HOT RUNNER SYSTEMS
 HOT RUNNER SYSTEMS
Valve gate systems control gate opening and
closing through a rod operated via a
pneumatic circuit. In this case it is possible to
operate with high injection diameters without
affecting the part aesthetical appearance. In
addition, the larger injection diameter
permits very low filling times to be achieved
without incurring in speed gradients in
excess. This also permits cycle time
improvements since lower temperature of
both molten material and mould can be used.
This also results in shorter cooling times
HOT RUNNER SYSTEMS
 HOT RUNNER SYSTEMS
Valve gate systems control gate opening and
closing through a rod operated via a
pneumatic circuit. In this case it is possible to
operate with high injection diameters without
affecting the part aesthetical appearance. In
addition, the larger injection diameter
permits very low filling times to be achieved
without incurring in speed gradients in
excess. This also permits cycle time
improvements since lower temperature of
both molten material and mould can be used.
This also results in shorter cooling times
 HOT RUNNER SYSTEMS
Valve gate systems control gate opening and
closing through a rod operated via a
pneumatic circuit. In this case it is possible to
operate with high injection diameters without
affecting the part aesthetical appearance. In
addition, the larger injection diameter
permits very low filling times to be achieved
without incurring in speed gradients in
excess. This also permits cycle time
improvements since lower temperature of
both molten material and mould can be used.
This also results in shorter cooling times
 HOT RUNNER SYSTEMS
Valve gate systems control gate opening and
closing through a rod operated via a
pneumatic circuit. In this case it is possible to
operate with high injection diameters without
affecting the part aesthetical appearance. In
addition, the larger injection diameter
permits very low filling times to be achieved
without incurring in speed gradients in
excess. This also permits cycle time
improvements since lower temperature of
both molten material and mould can be used.
This also results in shorter cooling times
The objective of a Hot Runner
System is to distribute the
material from the machine
nozzle to each gate, while
minimizing adverse effects to
the material’s properties.
Two hot runner system types:
• Complete Hot Runner System
• Manifold System
A complete hot runner system
is supplied to the customer as a
fully assembled unit, ready to
be fastened to the cavity plate
and installed into the machine
press
A manifold system includes all
components that make up the heated
flow path except the hot runner plates.
Drawings that outline the necessary
plate machining to accommodate the
manifold and related components are
included with every shipped manifold
system
The simplest hot runner mould for
replacing the conventional sprue
bushing including the reversed sprue
busing with a hot sprue bushing or
heated nozzle.It feeds directly into
the cavity and has the the following
advantages:
-Control of temperature
-Substantial independence of
material and cycle
-Suitable for large moulds
-Less pressure drop and clean gate
separation.
The purpose of the nozzle is to provide a now path for the plastic
melt from the machine's cylinder to the mould. In the simplest
design the nozzle butts on to the sprue bush of the mould. There are
two standard designs in common use and they differ only with
respect to the form of seating that is made with-the sprue bush .One
design incorporates a hemispherical end and the other design is flat-
ended. The small length of reverse taper in the bore at the front end
of the nozzle is such that the sprue is broken just. inside the nozzle.
This helps to keep the nozzle face clean and assists in maintaining a
leak-free sealing face. The standard nozzle of either design is
provided by the machine manufacturer und, so that moulds are
interchangeable, it is advantageous for a company to standardize on
one particular design.
It is an advantage to keep the length of the sprue
gate as short as possible to minimise the pressure
drop across the gate and also to minimise the
blemish left on the moulding when the sprue gate is
removed.With the standard nozzle design the length
of the sprue gate is controlled by the depth of the
mould plate. The length of the sprue gate can be
reduced quite simply, however, by designing a
special nozzle variously termed a long reach nozzle
or extended nozzle which protrudes into a pocket
machined in the mould plate
Some means of heating the nozzle must be provided
lo prevent undue cooling of the plastics material. One
method is to fit a resistance-type band heater on to
the parallel length of the nozzle and to control the
temperature by means of a controller via a
thermocouple- The thermo­couple is fitted into a slot
machined into the parallel section of the nozzle
directly beneath the heater band.
To minimise the transfer of heat from the heated
nozzle to the mould, a circumferential clearance of at
least 7 mm must be provided between the two parts
The conventional sprue gate results in a sizeable
blemish being left at the injection point. Now, for the
majority of components this blemish is unimportant,
but there are occasions where it is undesirable. To
reduce it to a minimum some form of pin gate is
necessary. One method of achieving this form of
gate is by the use of a special nozzle in conjunction
with a reverse tapered sprue.This special nozzle is
variously termed as barb nozzle or Italian nozzle.
The barb nozzle is similar to the standard nozzle except that
there is a projection at the front which incorporates barbs It is
this portion of the nozzle which is accommodated in the
reverse-tapered -sprue. Leakage of material is prevented by
ensuring that the flat face the nozzle seats on to the sprue
bush .
The sprue is normally removed manually from the nozzle
which of necessity, lengthens the moulding cycle. An
alternative design incorporates a local stripper plate, to strip
the sprue from the barbs. The barb nozzle design has largely
been superseded by ante-chamber and hot sprue bush

designs.
In this design, also known as the hot well design, a
small mass of plastic material is retained in the
antechamber The plate material adjacent to the
mould wall partially insulates the central core plastic
material in antechamber. Thus, by suitable
adjustment and control of the nozzle temperature
and the moulding cycle, the material remains
sufficiently fluid to allow it to pass intermittently
through the ante chamber into the impression,
As it is not necessary to remove the sprue from the
mould, fast moulding cycles can be achieved. Note
that with a standard nozzle the moulding cycle,
particularly with thin-walled components, is often
controlled by the waiting period for the sprue to cool
sufficiently to permit its extraction.
A part-section through a mould for a thin-walled
beaker which incorporates the antechamber design
is illustrated .In this single impression mould, the
integer cavity is adopted for rigidity. A local insert
forms the base of the impression, and also
incorporates the antechamber . The nozzle has a
seat on the insert
There are two heated sprue systems which can be
used for feeding directly into an impression. In one
system, in which the conventional sprue bush is
replaced by an internally healed sprue bush. the
concept of the injection machine's nozzle abutting
onto the sprue bush is retained. In the alternative
system the sprue bush is dispensed with. being
replaced by an internally heated extension nozzle.
Internally heated sprue bush: The principle of
this design is that a healing element is incorporated
on the centre line of the sprue bush in the flow-way
between the injection machine's nozzle and the gate
(entry) into the impression. By this means, the
polymer material may be held at an elevated,
controlled temperature up to a position relatively
close to the gate- A standard injection machine
nozzle, with either a flat or a radius end, is used in
conjunction with this design
Internally heated sprue bush: One design of
internally heated sprue bush is illustrated in Figure
and consists of five basic parts: (a) body-outer, (b)
body-inner, (c) torpedo, (d) torpedo tip and (e)
cartridge heater. The cartridge heater is housed
within the torpedo assembly, as shown. The heater
wires pass through one of the torpedo legs via an
internal insulator and adaptor (f). The torpedo
assembly is mounted within the body-inner which is
then screwed into the body-outer to form the sprue
bush.
A part-section through a mould for a thin-walled
beaker which incorporates the antechamber design
is illustrated .In this single impression mould, the
integer cavity is adopted for rigidity. A local insert
forms the base of the impression, and also
incorporates the antechamber . The nozzle has a
seat on the insert
A part-section through a mould for a thin-walled
beaker which incorporates the antechamber design
is illustrated .In this single impression mould, the
integer cavity is adopted for rigidity. A local insert
forms the base of the impression, and also
incorporates the antechamber . The nozzle has a
seat on the insert
Cavity Design
Design Guidelines

Recessed Gate Areas

When designing gates into recessed areas such as dimples, a
generous radius should be incorporated to avoid extended thin
sections of plate steel (see figure at right).
Nozzle Seal off Diameter
To provide a durable nozzle seal diameter surface in the gate
bubble, a surface hardness range between 49 - 53 Rc is
recommended (see figure at right). If softer materials are used
(e.g. BeCu), these should be hard chrome plated to increase
hardness.
Gate Cooling
Gate area cooling is required to
remove excess heat generated
by
the system. Sufficient cooling
provides many benefits
including:
• Consistent gate quality
• Consistent gate vestige
• Greater control over material
stringing
• Greater control over resin
drool
• Greater control of gate
Optimized Gate Cooling (Key Elements)
1) Minimize the distance from the cooling channel to the
gate detail The maximum recommended distance
between the cooling channel and the gate detail is 1.5
times the cooling channel diameter.
2) Cooling should surround the insert. The cooling water
shouldreach flow speeds that cause effective mixing of
the fluid. For most inserts, a flow rate of about 6.8 - 8.3
liters perminute is sufficient.
3) The gate insert material affects heat dissipation and
longevity.Insert materials such as H13 (material of
choice) and 420 SS are 7x less heat conductive than
BeCu Alloys. The trade-off with conductivity is hardness
and gate life. Material choice will depend upon the
number of projected cycles and the cycle time goals,
Gate Inserts
Gate inserts provide an
effective method of cooling
the gate area, since the
entire circumference is
cooled. Cooling circuits for
the gate insert should be
independent from the plate
cooling circuit to provide
better control. The gate
insert is a replaceable wear
item.
Nozzle selection chart

Following data have to be taken into consideration:

flow length,
shear rate of resin,
wall thickness
and configuration of the molded part.
Sprue gate nozzles
Used where a small sprue on the part
or runner is not objectionable.Its
unrestricted channel is recommended
for molding filled materials, or larger
parts requiring maximum flow.
Provides extra stock on front face for
machining runner profiles and part
contours.
Ring gate nozzles
Used where a small circular
gate mark is permissible. Nickel
plated beryllium copper gate tip
controls plastic flow, provides
uniform heat transfer and
improves gate cosmetics.
Stack Mold
Stack Mold
Stack Mold
Extended sprue gate tips
Stack Mold
Stack Mold
Stack Mold
Multiple gate nozzles
System of operations:
The key to the system’s operation is
the method employed to open and
close each gate. In operation each
gate is opened or closed
independently and positively by a
hydraulic cylinder. Each valve is open
for only the time it takes to reach
optimum fill. This enables the molder
to eliminate the over packing of filled
cavities while trying to fill others.The
Full-body type nozzle is suggested
when a circular gate mark is allowed.
Feeding the part or runner, it features
a unique removable tip for easy
replacement and longer nozzle life.
The Body less type Gate offers
excellent cosmetics, feeding directly
into the part.
Hot-One system
Hot-One system
Galaxy Hot Runner Systems are engineered to reduce
cycle times and simplify start ups.Designed for high cavity
applications, without any performance compromises. Close
center-to-center dimensions yield more parts per cycle.
Galaxy nozzles are innovative and feature quick-change
modular assemblies for reduced service time. Galaxy
nozzles offer a choice of tips: standard, wear-reistant and
thru-hole. A modular nozzle construction enables a wide
range of nozzle lengths to suit a variety of mold stack
heights. Nozzle tips, heaters and thermocouples are front
loaded and easily replaced right in the machine.
Cold-runner Systems
- The standard single nozzle
plunges centraliy into the tool
- The single nozzle is fitted to
the machine nozzle to suit the
machine
- The needle is actuated by
means of an external
cylinder/lever unit
- The needle shut-off nozzle is
opened and closed by the
machine control unit
- Optimum thermal separation of
sprue system and contour unit
as far as the feed orifice area
- Specially for the filling of large-
Cold-runner System, Single decentralised nozzle
Cold-runner System,4-nozzle low system
Cool-One system - Basic concept
Cool-One system - Basic concept
Cool-One system - Basic concept
Multiple probes - complete
Guidelines for the construction of a distributor block
Hot sprue bushings