How an Automotive Supplier Improved Mold Cooling with a Double-Easy Mold Waterway Cleaning Machine

A related mold cleaning solution for automotive wheel hub suppliers provides additional industry and application context.

Case at a Glance

Item	Project Result
Industry	Automotive components
Customer profile	Tier 1 supplier under Volkswagen Group
Mold characteristics	Large molds with long cooling channels, complex passages, and multiple bends
Main problem	Scale and debris contributing to uneven cooling
Solution	Double-Easy Mold Waterway Cleaning Machine
Mold disassembly	No longer required during cleaning
Large-mold cleaning efficiency	Improved by 65%
Surface qualification rate	Increased by 9%
Mold service life	Extended by 30%
Reported annual savings	More than RMB 630,000

Customer Background

The customer is an automotive wheel hub component supplier and a Tier 1 supplier under Volkswagen Group.

The company manufactures injection-molded decorative components for automotive wheel hubs.

Its large molds contain:

1. Long cooling channels

2. Complex internal passages

3. Multiple bends

For another production setting, review this automotive and die-casting mold waterway cleaning case.

These characteristics made routine cooling-channel maintenance more difficult.

The Production Challenge

Before introducing the Double-Easy system, the manufacturer relied on conventional cleaning methods for its large molds.

The manufacturer experienced several problems:

1. Long cleaning times

2. Incomplete removal of internal deposits

3. Uneven mold cooling

4. Surface color variation on decorative components

5. Deformation defects affecting appearance quality

6. Frequent mold disassembly

7. High labor requirements

8. Repeated maintenance affecting mold service life

The manufacturer needed a more effective way to clean complex internal cooling channels while reducing the maintenance workload.

Technical Analysis

The large size of the molds and the complexity of their cooling-channel structure made conventional cleaning methods less effective.

The main contributing conditions included:

1. Long cooling channels

2. Multiple channel bends

3. Internal scale accumulation

4. Internal debris deposits

These conditions made it difficult to completely clean the cooling circuits using the manufacturer's previous process.

The remaining deposits contributed to uneven cooling performance and increased maintenance requirements.

The Double-Easy Mold Waterway Cleaning Solution

The manufacturer introduced a Double-Easy Mold Waterway Cleaning Machine into its mold maintenance process.

The equipment incorporates high-speed, high-pressure water-vapor hybrid technology, identified as DBHM.

The system provided:

1. High-speed air-burst cleaning

2. Bidirectional flushing along internal channel walls

3. Cleaning of long and curved cooling channels

4. Removal of adhered scale and debris

5. Cleaning without mold disassembly

The cleaning process was intended to improve cleaning completeness while reducing labor intensity.

Equipment Configuration

The cleaning system included:

1. Mitsubishi variable-frequency drives

2. PLC control technology

3. Grundfos variable-frequency pump

4. Keyence ultrasonic flow meter

These components allowed the cleaning pressure and cleaning frequency to be adjusted while supporting stable cleaning performance and real-time monitoring of flow changes.

Implementation

The manufacturer integrated the Double-Easy Mold Waterway Cleaning Machine into its mold maintenance process.

Mold disassembly was no longer required during the cleaning process.

The equipment was configured according to the structural characteristics of the company's large automotive wheel hub molds by adjusting cleaning pressure and cleaning frequency.

During cleaning, the Keyence ultrasonic flow meter monitored flow changes while the system performed bidirectional flushing through the cooling channels.

Measurable Results

After implementation, the manufacturer reported:

1. Large-mold cleaning efficiency improved by 65%

2. Decorative-part surface qualification rate increased by 9%

3. Mold service life extended by 30%

4. Annual labor, maintenance, and rework savings exceeded RMB 630,000

5. Mold disassembly was no longer required during cleaning

Key Project Outcomes

The cleaning system helped the manufacturer:

1. Improve cleaning efficiency for large molds

2. Remove scale and internal debris

3. Clean long and curved cooling channels

4. Reduce labor intensity

5. Lower maintenance costs

6. Improve decorative-part surface quality

7. Extend mold service life

What This Case Demonstrates

This case demonstrates the importance of cleaning internal cooling passages when large automotive molds contain long channels, multiple bends, scale, and debris.

For this manufacturer, the Double-Easy Mold Waterway Cleaning Machine provided bidirectional cleaning of complex cooling passages without requiring mold disassembly.

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