The HB-THERM Thermo-5 is a digital temperature control unit purpose-built for injection molding and similar industrial temperature control processes. It is part of a series that has surpassed 100,000 units in operation worldwide, making HB-THERM the global market leader in this segment. The Thermo-5 regulates mould temperatures through a liquid heat carrier by controlled inducing or dissipating of heat, ensuring consistent part quality and efficient cycle times. Available in four housing sizes with temperature ratings of 100 °C, 140 °C, and 160 °C, it covers a wide spectrum of injection molding applications—from small cleanroom medical moulding machines to large automotive multi-cavity systems.

Temperature Control Precision and Self-Optimizing Regulation

• ±0.1 °C Control Precision: The Thermo-5 achieves highly accurate temperature control with a self-optimizing regulation algorithm that continuously adapts to the thermal load of the mould. This precision directly translates to consistent part dimensions, surface finish, and weight—critical for industries such as medical, optical, and automotive where even minor temperature variations can cause dimensional instability.
• Direct Cooling (Tankless System): The tankless hydraulic design with indirect cooling means that only the necessary amount of heat transfer fluid is used at any time. This design provides short heating and cooling times because there is no thermal inertia from a large reservoir of fluid—the unit heats or cools only the fluid that the mould actually needs in the moment.
• Heating and Cooling Capacity (Housing Size 4): The largest model delivers up to 32 kW of heating power and up to 110 kW of cooling capacity, making it suitable for the largest injection moulding machines where high thermal throughput is required for rapid mould temperature changes.

Energy-Efficient Pump Technology and Hydraulic Design

• Variable Speed Eco-Pump (IE4 Efficiency Class): All Thermo-5 units are equipped with a sealless stainless steel radial pump. Housing size 4 features a 2.2 kW pump circulating up to 220 L/min with a maximum head of 65 metres. The variable speed drive allows the pump to operate only at the speed required for the current process demand, and all energy savings are indicated and logged. This can save a considerable amount of energy compared to fixed-speed pumps.
• Energy-Optimised Circulation: The minimum circulation volume design requires less power, which directly reduces the heating and cooling energy consumed per cycle. The tankless system eliminates energy losses associated with maintaining a large fluid volume at temperature.
• Closed Hydraulic Circuit: The system operates without oxygen contact, with automatic deaeration and active pressure regulation. This closed design inhibits corrosion and improves the working life of the heat transfer fluid, reducing maintenance intervals and protecting the injection mould from internal oxidation and scaling.

Fully Automatic Process Monitoring and Safety

• Ultrasonic Flow Rate Measurement: High-precision ultrasonic sensors measure the actual flow rate without moving parts, providing accurate, drift-free measurement that does not degrade over time.
• Hose Rupture and Leakage Detection: The unit continuously monitors the hydraulic circuit and can detect a hose rupture or slow leakage, immediately alerting the operator and preventing water damage to the mould, machine, and factory floor.
• Corrosion-Resistant Materials: The entire hydraulic circuit is constructed from corrosion-resistant materials, and the heating elements operate without any direct contact with the heat transfer medium—a design unique to HB-THERM that substantially extends heater life and is backed by a lifetime warranty on the heating registers.
• Intelligent Monitoring: Due to intelligent monitoring of all processes, the units only notify operators when it is absolutely necessary, reducing alarm fatigue and focusing attention on genuine problems.

Data Recording, Integration, and Industry 4.0

• USB Data Recording: Process data can be recorded via USB and evaluated in Microsoft Excel, enabling process documentation for quality assurance, troubleshooting, and process optimisation without specialised software.
• Mould-Specific Parameter Storage: Parameters for each mould—temperature, flow rate, pressure limits, alarm thresholds—can be saved to the controller and recalled when the same mould is next installed. This reduces setup time and operator error during mould changes.
• OPC UA Interface (Optional): The OPC UA interface enables integration of the Thermo-5 into Industry 4.0 networks, allowing digitised worldwide communication between machines, systems, and higher-level manufacturing execution systems (MES).
• Integration with Injection Moulding Machine Controllers: Thermo-5 units can be integrated directly into the controller of injection moulding machines, allowing temperature to be managed as part of the machine's overall recipe and operation.

Versatile Sizes, Expandability, and Cleanroom Suitability

• Housing Sizes 1–4: From compact units for small machines to the 650 mm-high Housing Size 4 designed to fit below even the largest injection moulding machines without impinging on the overall plant footprint. The extruded aluminium casing with hinged top cover and gas spring provides easy access for maintenance.
• Modular Expansion: Up to 16 Thermo-5 units can be combined and controlled as a group. Companion devices include the Flow-5 flow meter, the Vario-5 switching unit for variothermal processes, and the Panel-5 universal remote control.
• Cleanroom Compatible: The Thermo-5 can also be used in a clean room, and draws attention only when necessary through its quiet operation—critical for medical and optical injection moulding environments where noise and contamination must be minimised.

Applications

• Injection moulding of precision parts requiring ±0.1 °C mould temperature stability (medical devices, optical lenses, electronic connectors)
• Multi-cavity injection moulding where uniform temperature distribution across all cavities is required for dimensional consistency
• Large automotive injection moulding (bumpers, instrument panels, door panels) requiring high heating and cooling capacity
• Cleanroom injection moulding for medical, pharmaceutical, and optical applications
• Industrial processes beyond injection moulding requiring precise liquid heat carrier temperature control
• Variothermal process applications when combined with the Vario-5 switching unit