Plastics Industry: Temperature Control Units for Injection Molding

Temperature control in injection molding tools is the primary factor influencing unit costs and part quality. ONI combines intelligent temperature control management with efficient cooling/distribution and machine efficiency (EtaControl®) to stabilize process windows and save energy.

  • Rhytemper® temperature control management: thermal “fingerprint” per mold circuit, active control of ΔT/flow rate, cycles ~18% shorter on average.
  • Efficient temperature control/chilled water technology on the market: e.g., PEM-based temperature control units and R290 chilled water solutions deliver verifiable energy and process benefits.
  • Machine optimization (EtaControl®): demand-based oil flow management significantly reduces electricity costs for conventional injection molding machines.

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Overview of the Site

Benefits for Plastics Customers

Why are temperature control units crucial in injection molding?

  • Higher OEE, less scrap
  • Transparent data/visualization: Reliable before/after metrics facilitate approval
  • Faster ROI from cycle time, quality, and energy efficiency improvements
  • Quality & process stability through intelligent temperature control
  • Energy efficiency through integrated PEM/R290 concepts
  • Scalability: from single-mold to plant-wide standard

Why you should choose ONI

Everything under one roof

This is how we bring your temperature control equipment project to life

To ensure optimal operation, we at ONI consider the interaction between the mold, the medium, the peripherals, and the process requirements.​

  • Temperature Control Audit (circuits, ΔT, flow rates, visualization)
  • Pilot test on a bottleneck tool, including before/after KPIs
  • Refrigeration/Distribution Match (PEM/R290, Water Distribution)
  • Rollout & Training (Maintenance/Process)
  • Commissioning & Process Stabilization
  • Operation, maintenance & transparency

Additional services

Challenges

Challenges in the plastics industry
 

Process Stability & Quality

  • Fluctuating quality due to uneven tooling/temperature (hot spots/cold spots)
  • Dimensional deviations, warping, surface defects despite identical settings
  • Sensitive start-up phases and unstable production conditions in injection molding

Cycle Time, Cooling & Productivity

  • Long cooling times slow down the cycle (especially for complex parts)
  • Insufficient or uneven cooling extends cycle time and reduces output
  • Potential remains untapped because heat is not effectively removed from the mold

Energy & Efficiency in Operation

  • High energy consumption due to inefficient control or improperly designed temperature control
  • Heating and cooling “working against each other” → unnecessary heat/cooling generation
  • Non-optimized media and circulation concepts (water/oil) increase operating costs

Complexity, Transparency, and Root Cause Analysis

  • Complex systems with many loops and different requirements for each zone
  • Missing measurement/process data (temperature, flow) → Optimization becomes “trial and error”
  • Malfunctions caused by contamination / air / leaks are difficult to detect without monitoring in the temperature control system

Solutions

ONI Solution Overview for the Plastics Industry

Cooling

Our ONI solutions:

To cooling systems
To rental
chillers To container cooling systems
To mobile cooling systems

To the overview

Heating

Our ONI solutions:

To Heat Recovery
To Industrial Heat Pumps
To Combined Heat and Power Plants

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Ventilation

Our ONI solutions:

Ventilation Systems
Cleanroom Technology

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Other solutions

To Ice Storage
To Battery Storage
To Compressed Air Systems

To cooling water
To cooling water treatment
To temperature control technology
To energy-efficient machine optimization

We provide comprehensive consulting services

Typical applications & requirements

  • Mass production: stable temperatures, short cycle times, quick changeover
  • Visible parts: uniform heat distribution for reproducible surfaces
  • Technical parts: consistent conditions for dimensional accuracy and functionality
  • Molds with multiple cavities: clear controllability, clean circuit structure, transparent status
  • Energy/efficiency programs: Reduce unnecessary heating and cooling without compromising quality

View references

Key Topics

Your ONI Contact

We’re happy to answer your questions!

+49 2266 4748-0
info@oni.de

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Your benefits

Why Choose ONI

Comprehensive
system solutions


ISO-certified

Assistance
with applications

24/7 service
worldwide


Over 40 years of experience

Patented
efficiency technologies

Financial stability
through CrefoZert

International
recognition

Our customers

These customers already trust us

Proven quality

References & Testimonials on Plastics

Melanie Lehmann | Oskar Lehmann, LLC

"We are very pleased that we chose an ONI system and look forward to continuing this excellent partnership. We still have a few projects to tackle here at our company, and we are delighted to have ONI as a partner by our side."

Bergi-Plast GmbH, based in Saxon Switzerland, has partnered with systems specialist ONI to implement a comprehensive, optimized supply concept.

Read more

 

Efficiency and environmental protection: two sides of the same coin

Read more

 

A comprehensive energy-saving plan for the injection molding shop.

Read more

 

View all references

Questions & Answers

FAQ on Temperature Control Units for Injection Molding

Common issues include inconsistent part quality, varying cycle times, sensitive start-up phases, or widely fluctuating mold temperatures despite identical settings.

That depends on the temperature range, the tool requirements, and your safety and operational procedures. Water is often efficient and cost-effective, while oil is typically used when there are specific temperature or process requirements.

Absolutely. When temperature and circulation patterns are visible, it’s easier to pinpoint the causes (e.g., contamination, air, leaks, or changes in heat dissipation) more quickly—rather than spending a long time “trying things out.”

In most cases, yes—it’s important to carefully plan the circuits, connection points, and interfaces so that the temperature control system is compatible with the equipment and remains easy to use on a day-to-day basis.