Frigel’s DYNAMICO™ DYD100VF in Syncro mode helped an automotive parts manufacturer boost productivity by 41%, cut cycle time by 27%, and complete recipe fine-tuning in just 2.5 hours — all while maintaining the surface finish and process stability required for a technical internal mounting component.
For manufacturers in the automotive sector, productivity, consistency and part quality are closely linked. Injection moulded components often need to meet demanding technical and visual standards, while also being produced at high volumes and competitive cost.
In this application, the customer was producing a technical automotive part used for internal car part mounting. The aim was to increase output and reduce cycle time, while maintaining the high-quality surface finish and process stability required for the finished component.
The Challenge
Cooling is one of the most important stages of the injection moulding process. Depending on the part, material and mould design, cooling time can account for a large proportion of the overall production cycle. Because of this, improving cooling performance can have a direct impact on productivity, energy efficiency and cost per part.
For this automotive application, the challenge was to reduce cycle time without compromising the appearance or quality of the moulded component. The part required a high level surface finish, meaning the process had to be carefully controlled. Faster cooling alone would not be enough if it caused quality issues, dimensional instability or inconsistent results.
The customer needed a solution that could improve heat transfer, optimise the cooling phase and provide repeatable mould temperature control throughout the cycle.
The Solution
To address this, the customer tested the Frigel DYNAMICO™ DYD100VF, operating in Syncro mode.
DYNAMICO™ is designed to provide dynamic mould temperature control for injection moulding applications, helping manufacturers improve cooling performance and increase productivity. Compared with standard temperature control units, DYNAMICO™ can deliver significantly higher flow rates, improving heat transfer and helping to remove heat from the mould more effectively.
A key feature of the system is its dual zone technology, which allows independent temperature control for each mould half. This gives processors greater flexibility and enables more precise control of the moulding process, particularly where surface finish, dimensional accuracy and cycle time are critical.
For the trial, the DYNAMICO™ unit was digitally connected to the mould using an external switch. This allowed the DYNAMICO™ unit and the injection moulding machine to work in synchronisation, enabling the customer to take full advantage of Syncro mode.
How Syncro Mode Works
Syncro mode (available only VFD pumps) is designed to optimise cooling performance by applying targeted flow and temperature control during the cooling phase of the moulding cycle.
Rather than cooling continuously throughout the entire process, Syncro focuses cooling power at the point where it delivers the greatest benefit. During the cooling phase, the system boosts flow and optimises temperature control to remove heat more efficiently from the mould. Once this stage is complete, the system then allows the natural cavity re-heat to support the rest of the cycle.
This intelligent approach helps reduce unnecessary cooling, improve process efficiency and shorten cycle times while maintaining part quality.
AI Assisted Recipe Optimisation
Operators also used the DYNAMICO™ Wizard software to fine tune the unit. This AI-assisted optimisation tool guided the process setup, helping the team identify the optimum recipe quickly and efficiently.
The recipe fine tuning was completed in just 2.5 hours, allowing the customer to establish the correct operating parameters with minimal disruption. This helped reduce the complexity usually associated with process adjustment and enabled the customer to achieve measurable results in a short period of time.
The Results
The implementation of Frigel DYNAMICO™ DYD100VF in Syncro mode delivered significant, measurable improvements:
41% increase in productivity
27% reduction in cycle time
Recipe fine tuning completed in just 2.5 hours
By reducing cycle time, the customer achieved a substantial increase in annual output from the same moulding cell. For a high-volume automotive application, this represents a major improvement in production capacity without the need for additional injection moulding machines or extra floor space.
The results demonstrate the impact that advanced mould temperature control can have on manufacturing performance. Instead of treating cooling as a fixed part of the moulding cycle, DYNAMICO™ allowed the customer to actively optimise it. This helped reduce wasted time, increase throughput and maintain the quality requirements of the finished part.
Improving Productivity Without Compromising Quality
For automotive injection moulders, this type of improvement is particularly valuable. Manufacturers are under constant pressure to produce more parts, reduce energy consumption, improve repeatability and maintain tight quality standards.
By improving cooling performance and reducing cycle time, Frigel DYNAMICO™ offers a practical way to increase productivity and reduce cost per part. The successful trial also highlights the value of intelligent, connected cooling technology in modern plastics processing environments.
Through Syncro mode, dual zone control and AI-assisted recipe optimisation, DYNAMICO™ delivered more than standard temperature regulation. It provided a controlled, data-driven approach to mould temperature management, helping the customer achieve a significant productivity gain in a short period of time.
Frigel DYNAMICO™ Available Through Summit Systems
With a 41% productivity increase, 27% cycle time reduction and recipe fine tuning completed in just 2.5 hours, this case study shows the potential impact of DYNAMICO™ technology for injection moulding applications where cooling performance is limiting output.
Frigel DYNAMICO™ is available to manufacturers across the UK and Ireland plastics industry through Summit Systems, helping injection moulders improve cooling performance, reduce cycle times and increase productivity without compromising part quality.
