Thermoregulator, as the name suggests, means a device that regulates and controls heat. The English-origin word thermoregulator is derived from the combination of thermal (related to heat, temperature) and regulator (controller). When these two concepts come together, they refer to machines that enable precise control of heat.
In industrial production methods, especially controlling mold temperatures is critical for producing high-quality products. This is because the materials used inside the mold (plastic, metal, rubber, etc.) gain their optimal physical properties within certain temperature ranges. If these temperatures constantly fluctuate or cannot be maintained at the correct level, both production efficiency decreases and significant losses in the quality of the produced parts occur. This is where thermoregulators come into play.
Basic Definition in Industry
A thermoregulator is a device designed to keep the temperature of any tool used in a mold or production process constant at the desired reference value. While doing this, it continuously measures, controls the temperature, and heats or cools the mold when necessary. In this respect, thermoregulators are considered one of the most critical components of heat transfer technologies.
Why is a Thermoregulator Needed?
Uncontrolled temperature in a production process can lead to many negatives:
• Inconsistent product quality: There may be differences in size, surface, or durability between products coming out of the same mold.
• Burrs and deformation: Excessive expansion or insufficient hardening of the material causes errors on the product.
• Energy loss: Excessive heating or cooling increases energy consumption, raising costs.
• Prolonged production time: If molds do not operate at the correct temperature, cycle times increase, and total production capacity decreases.
Considering these risks, thermoregulators become not just auxiliary equipment but an indispensable tool for the continuity, quality, and efficiency of production.
The Role of Thermoregulators Today
In modern production lines, especially in processes such as plastic injection molding, metal injection, extrusion, and casting, thermoregulators have become standard equipment. Additionally, thermoregulators are used wherever temperature control is decisive in the automotive, electronics, and medical device sectors.
Thermoregulators developed by engineering-focused companies like MIT not only maintain temperature stability but also make processes more flexible and reliable with their gradual heating and cooling capabilities. Thus, manufacturing companies meet high-quality standards and achieve energy efficiency.
The Importance of Thermoregulators in the Mold Industry
The mold industry is one of the most critical production areas of modern industry. The quality of parts produced by methods such as plastic injection, metal injection, casting, rubber processing, or extrusion is directly related to the temperature control of the mold. This is because the temperature inside the mold determines the freezing, shaping, and final hardening stages when the material contacts the mold surface.
If the mold temperature remains outside the desired range, the production process is adversely affected in terms of both quality and cost. This is why thermoregulators are indispensable assistants in production lines in the mold industry.
Precise Temperature Control and Product Quality
Correct adjustment of mold temperature affects many factors, from the surface quality of the product to dimensional precision. Thanks to thermoregulators:
• Homogeneous heat distribution is achieved. Thus, equal temperature is obtained on all surfaces of the mold.
• Quality standard is maintained. It is guaranteed that every part in mass production comes out with the same size and durability.
• Burr formation and deformation are prevented. Excessive heating or insufficient cooling causes burrs or material deterioration on the product edges. The thermoregulator minimizes these risks.
Contribution to Production Efficiency
One of the most important criteria in the mold industry is the production cycle time. Shortening the cycle time means producing more products in the same time frame. Thermoregulators:
• Ensure the mold reaches the necessary temperature faster.
• Optimize cooling and heating processes, shortening the cycle time.
• Offer both time and cost advantages by keeping energy consumption to a minimum.
Thus, manufacturing companies increase both capacity and competitiveness.
Reducing Waste and Raw Material Losses
Incorrect temperature settings in molding processes increase the rate of defective parts. Each defective part means both raw material loss and time loss. With thermoregulators:
• Product waste is reduced.
• Material spreads more accurately on the mold surface.
• Raw material efficiency increases.
This advantage directly affects production costs, especially in sectors such as automotive and defense industries where high-cost raw materials are used.
Energy Efficiency and Sustainability
As energy costs are increasing today, businesses are turning to sustainable production models. Thermoregulators provide the most efficient temperature management by:
• Preventing unnecessary heating and cooling cycles.
• Reducing energy consumption.
• Contributing to reducing the carbon footprint.
Thus, it offers benefits to companies not only economically but also environmentally.
Sectoral Areas of Use
In the mold industry, thermoregulators are critical in areas such as plastic injection, including;
• Automotive industry: Production of vehicle parts with precise measurements
• Electronics industry: Homogeneous production of small components
• Packaging industry: Thin-walled, fast production requiring products
• Metal and casting industry: Ensuring dimensional stability at high temperatures
• Medical production: Obtaining sterile and error-free products
Thermoregulators play a critical role in such areas.
Working Principle of Mold Temperature Control Devices
Thermoregulators, or mold temperature control devices, are high-precision equipment that keeps the temperature constant within a certain range in production processes. These devices work based on a measure-compare-correct cycle. That is, the device continuously measures the mold temperature, compares this value with the reference value set by the user, and activates the necessary heating or cooling processes when there is a deviation.
This principle, although simple, plays a very important role in production processes. Because even a few degrees of deviation can cause serious problems in product quality. This is why thermoregulators are equipped with advanced technologies.
1. Temperature Sensing (Sensors)
One of the most critical parts of mold temperature control devices is temperature sensors.
• These sensors are placed inside or on the surface of the mold.
• They measure the temperature instantly and send data to the control unit.
• The accuracy and response time of the sensors used determine the sensitivity of the entire system.
For example, sensors operating with ±0.1°C accuracy directly affect quality, especially in sectors requiring millimetric measurement like plastic injection.
2. Control Unit (Brain)
The data from the sensors is transmitted to the device's control unit. Here:
• The measured temperature is compared with the target temperature.
• If a difference is detected, the system automatically activates the heating or cooling elements.
• Modern devices usually use PID control algorithms. This algorithm prevents sudden fluctuations, keeping the temperature more stable.
The control unit also provides information to the operator through a user-friendly screen. Thus, temperature data in the production process can be monitored instantly.
3. Heating and Cooling Elements
The part of mold temperature control devices that can be defined as "muscle power" is the heaters and coolers.
• Heaters: Operate with electric resistances and quickly bring the mold to the target temperature.
• Coolers: Usually work integrated with a chiller (cooling unit) or heat exchanger systems. They activate when necessary to lower the temperature.
Thus, the device can carry out both heating and cooling functions within the same system.
4. Liquid Circulation (Heat Transfer)
One of the most common working principles of thermoregulators is using a heat transfer fluid.
• This fluid can mostly be water or thermal oil.
• The fluid is heated or cooled by the device.
• It is then circulated through special channels or jackets inside the mold.
• As the fluid passes through the mold, it transfers its heat, thus regulating the mold temperature.
This closed-loop system provides both energy savings and prevents temperature fluctuations.
5. Regulation and Feedback Loop
The device does not make a one-time adjustment. There is a continuous feedback loop:
1. The sensor measures the temperature.
2. The control unit compares this value with the reference.
3. The heater or cooler is activated.
4. The temperature is measured again.
5. The system continuously repeats this loop.
Thanks to this loop, the mold temperature is kept constant within the desired range.
Contribution of the Working Principle to Production
This technical structure provides the following advantages in production:
• Precise temperature control: Ensures that each part is produced with the same quality.
• Shorter production cycle: Quickly reaching the correct temperature of the mold shortens the cycle time.
• Low energy consumption: Prevents unnecessary heating-cooling cycles.
• Reduced error margin: Minimizes defects such as burrs, deformation, or cracking.
Advantages of Using Thermoregulators
The primary goal of every piece of equipment used in the industry is to increase production quality while reducing costs and making processes more efficient. Thermoregulators are one of the most concrete examples of this principle. The advantages provided by mold temperature control devices not only enhance production quality but also offer significant contributions to businesses in terms of energy efficiency, sustainability, and cost management.
Below you can find the main advantages of using thermoregulators in detail:
1. High Quality and Homogeneous Products
One of the most important elements in molding processes is homogeneous heat distribution. Thanks to thermoregulators, every point of the mold reaches the same temperature, which directly affects the surface quality of the products.
• Smoother surfaces are obtained.
• Dimensional precision is maintained.
• All parts in mass production carry the same quality standard.
This advantage provides a competitive edge to the manufacturer, especially in sectors with high-quality expectations such as automotive, medical, and electronics.
2. Shorter Cycle Times
In production, "time" is a resource as valuable as raw material. Thermoregulators:
• Ensure molds reach the necessary temperature faster.
• Optimize cooling and heating processes.
• Shorten waiting times in each cycle.
This means more product production in the same time frame. In other words, thermoregulators increase capacity, enhancing the efficiency of the business.
3. Minimizing Errors and Losses
Incorrect temperature settings lead to problems such as cracking, burr formation, and deformation in products coming out of molds. These errors mean both raw material waste and time loss. Thanks to thermoregulators:
• Temperature fluctuations inside the mold are prevented.
• Thermal stresses are minimized.
• The risk of distortion, shrinkage, and cracking in products is reduced.
As a result, less scrap and more quality products are obtained.
4. Energy Efficiency
As energy costs increase day by day, solutions that provide energy savings have become critical for production facilities. Thermoregulators optimize energy consumption by only heating and cooling as needed.
• Prevent unnecessary energy consumption.
• Reduce total energy costs in the production process.
• Help reduce the carbon footprint of businesses.
This advantage is of strategic importance, especially for companies adopting environmentally friendly production policies.
5. Product Reliability and Consistency
Thermoregulators ensure that each part is produced under the same conditions during the production process. This means standardized production.
• All parts come out with the same characteristics.
• Quality control processes in mass production become easier.
• Customer satisfaction increases.
Thus, companies gain not only a cost advantage but also brand reliability.
6. Wide Range of Applications
The advantages provided by thermoregulators make them indispensable in different sectors. In plastic injection, metal casting, rubber molding, automotive parts production, electronic components, and even medical device production, thermoregulators ensure the safe and quality progression of processes.
Types of Thermoregulators
Mold temperature control devices, or thermoregulators, are designed in various types to meet the requirements of different production processes. Because each sector, material, and production method requires different temperature ranges, different heat transfer speeds, and different levels of precision. Therefore, thermoregulators are generally divided into two main categories: water-based and oil-based. Each system has its unique advantages, areas of use, and limitations.
1. Water-Based Thermoregulators
Water-based thermoregulators use water as the heat transfer fluid. It is one of the most commonly preferred solutions in the industry.
Features:
• Provides fast heat transfer thanks to the high heat capacity of water.
• Generally operates efficiently in the 90–120°C temperature range.
• Investment cost and operating expenses are lower compared to oil-based systems.
Advantages:
• Economical, with low operating costs.
• Provides fast cooling, thus shortening production cycles.
• Can be easily integrated due to their simple and compact structures.
Disadvantages:
• Effectiveness decreases at high temperatures (above 120°C).
• May require additional maintenance against issues like scaling, corrosion, or evaporation.
Areas of Use:
• Plastic injection molding
• Packaging industry
• Electronic component production
• Productions requiring fast cycle times
Water-based systems are an ideal solution for sectors operating in the medium temperature range.
2. Oil-Based Thermoregulators
Oil-based thermoregulators use thermal oil as the heat transfer fluid. These devices stand out in processes requiring high temperatures.
Features:
• Provides temperature control that can reach up to 200°C and even 350°C in some special designs.
• Thermal oil operates stably at high temperatures as it does not evaporate.
• Can be used in a wider temperature range.
Advantages:
• A reliable solution for molds requiring high temperatures.
• Provides more stable and consistent temperature control.
• Eliminates the risk of corrosion compared to water.
Disadvantages:
• Initial investment cost and operating expenses are higher.
• Thermal oils need to be replaced over time as they age.
• Requires stricter safety measures against oil leakage or combustion risk.
Areas of Use:
• Metal injection molding
• Casting industry
• Rubber molding
• High-temperature applications in the automotive and defense industries
Oil-based systems are preferred in sectors requiring high temperature and long-term durability.
3. Water-Based or Oil-Based?
Which thermoregulator to use in a production process depends on the following criteria:
• Required temperature range: Generally, water-based is preferred for below 100–120°C, and oil-based is preferred for 150–300°C.
• Material type: Water-based is usually sufficient for plastic, while oil-based devices are necessary for metal and rubber.
• Production cycle: Water-based is preferred in sectors requiring fast production, while oil-based is preferred in sectors requiring high precision and stability.
• Cost calculation: Companies wanting low initial investment turn to water-based, while oil-based may be more economical for long-term high-temperature needs.
Applications of Thermoregulators
Thermoregulators are devices used in all production processes where temperature sensitivity is critical in the industry. Their ability to undertake heating and cooling functions simultaneously makes them indispensable not only in the mold industry but also in many different sectors. If we consider their areas of use sector by sector, we can see that thermoregulators play important roles in a wide range.
1. Plastic Injection Molding
Plastic injection is one of the most common production methods. Plastic granules are melted, injected into the mold under high pressure, and cooled inside the mold to obtain the final product.
• The temperature of the mold directly affects the dimensional accuracy and surface quality of the plastic part.
• The thermoregulator ensures the plastic solidifies evenly inside the mold.
• Burrs, shrinkage, and surface errors are minimized.
• Consistency is maintained between parts in mass production.
Thermoregulators are a standard need, especially in the production of sensitive products such as automotive interior trim parts, electronic device cases, and medical equipment.
2. Casting Industry
In processes where metals or alloys are melted and poured into molds, the mold temperature determines how the metal spreads on the mold surface.
• Oil-based thermoregulators, resistant to high temperatures, stand out in this sector.
• Incorrect temperature control causes the metal to cool unevenly, leading to defects such as cracks and pores.
• Thanks to the thermoregulator, a more durable and homogeneous structure is obtained in casting parts.
This situation is of critical importance, especially for parts produced for defense, automotive, and heavy industry.
3. Rubber Molding
The molding of rubber and rubber materials also requires high-temperature control.
• Incorrect adjustment of the temperature in the mold directly affects the flexibility and strength of the rubber.
• Thanks to the thermoregulator, the desired properties in rubber products are guaranteed.
• Additionally, the production cycle shortens, increasing efficiency.
Thermoregulators play an important role in the production of products such as automobile tires, seals, and industrial rubber parts.
4. Extrusion Processes
Extrusion is the process of obtaining a continuous product in a specific form by passing the raw material through the mold.
• Here, the mold temperature plays a critical role in the dimensional stability of the product.
• The thermoregulator is used especially in plastic and aluminum extrusion.
• Keeping the temperature stable increases both the surface smoothness and durability of the product.
Thermoregulators are at the heart of the process in products such as pipes, profiles, and cable coatings.
5. Metal Injection Molding
The shaping of metal powders or liquid metals by injecting them into the mold under pressure requires high-temperature resistance.
• Oil-based thermoregulators are frequently preferred here.
• Incorrect temperature control may cause the metal not to fit properly in the mold.
• Thanks to the thermoregulator, both dimensional precision and mechanical strength are maintained in the products.
Automotive engine parts, small metal components, and precision machine parts are the most well-known examples of this method.
6. Automotive Industry
The automotive industry is one of the broadest application areas for thermoregulators.
• In the production of plastic parts by injection,
• In casting processes of engine and metal parts,
• In the molding of rubber components,
thermoregulators ensure both high quality and low production errors. This provides reliability in mass production in the automotive sector.
7. Electronics and Medical Industry
Parts used in the electronics and medical sectors have much more precise tolerances.
• Temperature fluctuations in electronic circuit components, micro plastic parts, or medical device parts can lead to production errors.
• Thanks to thermoregulators, standard quality is maintained in such products.
• Additionally, in medical production, hygiene and reliability are supported by correct temperature control.
MIT Thermoregulator Solutions
MIT engineering, known for its reliability in various sectors in Turkey and worldwide, develops innovative and high-performance systems not only in heat transfer products but also in thermoregulator solutions. MIT thermoregulators are designed to provide precise temperature control in production processes and are produced to meet the needs of different sectors with both water-based and oil-based options.
MIT Engineering's Approach
MIT adopts the principles of energy efficiency, high precision, and long-lasting use in every product it develops. Thermoregulator solutions are a reflection of this understanding:
• Processes are managed more controlled with gradual heating and cooling technology.
• All devices are equipped with PID-controlled microprocessor-based systems, minimizing temperature fluctuations.
• Designed with user-friendly interfaces to facilitate the work of operators in industrial use.
These features make MIT thermoregulators not just a device but a strategic part of the production line.
Outstanding Features of MIT Thermoregulators
1. High Precision: Provides flawless quality standard in mass production with temperature control precision up to ±0.1°C.
2. Flexible Use: Can be used in both low-temperature requiring plastic injection molds and high-temperature requiring metal injection molds.
3. Energy Efficiency: Offers lower energy consumption with special insulation and optimized heating/cooling systems.
4. Durable Design: Suitable for harsh conditions with a stainless steel body, industrial pump, and long-lasting resistance systems.
5. Advanced Safety Systems: Equipped with automatic protection mechanisms against risks such as overheating, low flow, and pressure fluctuations.
6. Easy Integration: Can be easily integrated into different production lines and works compatible with existing automation systems.
Sectoral Advantages
MIT thermoregulators offer customized solutions to meet the needs of different sectors:
• Plastic Injection: Increases the surface quality and dimensional precision of parts, prevents burr formation.
• Metal Casting: Works stably at high temperatures, preventing crack or pore formation in the metal structure.
• Rubber and Rubber Molding: Preserves the elasticity and strength of the material.
• Automotive and Electronics: Provides consistency and standard quality in mass production.
• Medical and Hygienic Production: Helps ensure safe production in sterile conditions with uninterrupted temperature control.
The Difference of MIT
The most important difference that distinguishes MIT thermoregulators from competitors is the customer-oriented engineering approach. In addition to standard products, special designs can also be made according to customer demands.
• Pumps in different capacities,
• Special thermal oil systems for high-temperature resistance,
• Special insulation solutions,
• Optimized heat transfer circuits for energy savings
are just a few of the customized options offered by MIT.
Conclusion: Thermoregulators for Efficiency and Quality in Industry
In the modern production world, competition is based not only on producing more but also on producing more quality, more efficiently, and more sustainably. At this point, thermoregulators, or mold temperature control devices, have become an integral part of industrial processes.
Keeping the temperature constant and controlled in molding processes directly affects both product quality and contributes to reducing costs by increasing the energy efficiency of businesses. Every part produced with correct temperature management has the same dimensional accuracy, surface quality, and durability. Thus, while standard quality is ensured in production, scrap rates decrease, and customer satisfaction increases.
From the Efficiency Perspective, Thermoregulators
• Shortening cycle times allows businesses to reach more production capacity at the same time.
• Significant reductions in production costs are achieved by providing energy savings.
• Economic and environmental benefits are provided by reducing raw material waste.
With these features, thermoregulators are not just an auxiliary device but a strategic investment tool that increases production efficiency.
From the Quality Perspective, Thermoregulators
• Prevent quality issues such as burrs, shrinkage, and deformation with homogeneous heat distribution.
• Consistency is guaranteed in the production of high-precision parts.
• Increases the competitive power of manufacturers in sectors where high standards are mandatory, such as automotive, medical, and electronics.
MIT's Contribution
Thermoregulators developed by MIT engineering not only meet standard needs but also provide long-term advantages to businesses with their gradual heating-cooling technologies, advanced control units, and energy-friendly designs. By offering both water-based and oil-based options, they develop solutions suitable for the needs of each sector.