How to choose the right side gate solution

The Place for Side GatesSide gate hot runners are one of the latest developments in the injection molding market, and are especially suited for deep cylinders such as pipettes, syringe barrels, and other small products that cannot be perfectly poured using traditional hot runners due to the lack of a flat surface. Side-gated hot runners offer numerous benefits for such applications, such as direct feed into products that would traditionally require a cold runner; raw material and time savings by eliminating additional downstream processing; better product quality than cold runners even when cast directly from side-gated hot runners; shorter injection times; ease of maintenance; design flexibility; and excellent performance over a wider range of molding temperatures. Now that more and more hot runner manufacturers are offering side gate hot runners, it is becoming increasingly important for injection molders to find the most appropriate side gate hot runner system by looking at the different products on the market, understanding the benefits of each and comparing them to their own needs. Side gate hot runners are one of the latest developments in the injection molding marketPrioritizing product qualityProduct quality has always been a priority for molders, and is even more important for certain industries where side gate hot runners are frequently used, such as the medical market. Gate quality is an aspect of the product that is scrutinized and carefully evaluated. Hot runners have the greatest impact on gate quality, and it is important for injection molders to carefully evaluate which side-gate hot runner will achieve the quality required by the customer. The gate quality achieved by different types of side-gating hot runners can vary significantly. Some side-gating solutions will outperform others in producing high quality products, while some models will provide the lowest gate marks. When it comes to overall product quality, side gate hot runners that allow the use of a single cavity mold are often preferred. Because a single cavity mold eliminates the misalignment that can exist in a two-piece split cavity, it generally achieves better product quality. In a split-cavity design, misalignment of the two cavities can create "parting lines" or excess plastic residue on the finished product where the cavities overlap. Single cavity designs also provide better cooling, further improving product quality and productivity. Side gate hot runners such as Husky's Ultra SideGate are side gate products designed with product quality as the first priority. the Ultra SideGate delivers accuracy and repeatability, with virtually zero (0.05 mm) gate marks, allowing for higher quality products to be produced in single cavity molds. Reliability and Ease of MaintenanceWhen choosing a side gate hot runner, it is also important to consider things like ease of maintenance. For molders, system uptime is even more important, as any time an injection molding machine is out of service can mean lost production and revenue. Reliability and ease of maintenance, availability of schedules, etc. are huge advantages for molders, allowing them to keep equipment and molds safe and up and running faster. For most molds, the injection nozzles that go into the hot runner require that the mold be removed from the injection molding machine before the mold can be put back into service. Side gate hot runners such as Husky's Ultra SideGate allow access to any individual nozzle without removing the mold from the machine - a huge advantage and time saver for molders. When the mold can be accessed without removing it from the machine to a separate nozzle, it becomes quick and easy to perform maintenance, allowing the machine and mold to be back up and running faster. Time is money when it comes to equipment uptime, and of course "space is money". Each mold has a limited amount of space, and that space must be used as efficiently as possible. The cleaner and more compact an injection mold is, the more products can be produced in the same amount of space, while maintaining the same level of productivity. Because the nozzles of a side gate hot runner are mounted on the side of the nozzle holder, as opposed to the bottom side of a conventional hot runner, side gate hot runners allow for multiple nozzles to be mounted on each piece of the nozzle holder, resulting in more cavities in the same size mold. This is a huge benefit to molders, especially those who are space conscious. In addition to the ability to install more nozzles per nozzle holder, the minimum spacing between nozzle heads, such as the Husky Ultra SideGate, is as small as 55 mm, which further maximizes space utilization and allows for more cavities in a smaller die holder. In most cases, the new technology requires different or unique operational steps. This is the case with many of the side-gated hot runners currently on the market. Learning and running a different set of operating procedures creates additional challenges for the molder, lengthens the ramp-up period and increases the cost of personnel training. By choosing a set of side gate hot runners that operate in the same way as traditional hot runners, it is easier to seamlessly integrate new molds. Some side-gate hot runners also require a separate, specific thermostat to manage mold startup and shutdown. Integrating a side gate solution that is compatible with a customer's existing thermostat system will save them time and money and provide production flexibility. For injection molders in need of a side-gating solution, it is important to understand the differences between the different side-gating hot runners on the market and the benefits each offers. While most side-gating hot runners serve a similar purpose, the quality, size and convenience they each offer can vary greatly. Taking the time to understand your customer's needs and integrating a set of side gate hot runners that best suits their needs can go a long way in helping you stand out in your industry.