Global leaders in release innovation.
Release agents are an integral part of many manufacturing processes. Specialty release agents can help you enhance productivity, extend tool/die/mold life, increase cycle times, improve part/surface quality, and reduce scrap and defect rates, along with many other potential benefits.
We work closely with you and your team to find the precise release agents to improve your processes.
Semi-Permanent Release Agents
You can leverage a number of potential advantages with today’s highly sophisticated water-based or solvent-based semi-permanent mold release agent technologies. Semi-permanent mold release technology has provided industries with a viable alternative to the traditional “shop-spray” or high-volume, apply-every-cycle release agent. Our customers have experienced:
- More mold releases between applications than conventional release solutions
- More molding cycles attained per working shift
- Small amount of product needed per application, contributing to a cleaner working environment with fewer storage needs
- Reduction in overall scrap
- Molds can remain in production for extended periods of time due to the protection properties provided
- Supports production of complex part/mold structures due to ease in application exactness
- Molded parts retain consistently good cosmetic appearance
Silicone-Free Release Agents
Always on the cusp on innovation and sustainability, Chem-Trend has developed a robust range of release agents that do not utilize silicone. Silicone-free release agents provide a number of benefits:
- Reduce oily residue, allowing for easier painting and coating post-release
- Reduce contamination risk and remove costly steps from the manufacturing processes
- Provide for the removal of costly and time-consuming steps in the manufacturing process of many components, thus increasing productivity and lowering your operational cost
Why should you choose Chem-Trend release agents?
Creating value for you, our customer, is our focus. Formulated to optimize your daily operations, our industry-leading line of release agents includes water-based and solvent-based products as well as silicone and silicone-free products in semi-permanent or apply-every-cycle products. Our solutions can help you overcome costly manufacturing challenges — and leveraging the power that release agents offer to improve operational efficiencies and product quality.
Chem-Trend offers a wide variety of release agent options suited to address your specific needs and maximize your results. Every molding process is unique in some way, and optimal release requires unique solutions. Our team of localized experts takes a hands-on approach, working with you to identify all areas of potential improvement. Our research and development team then designs individualized solutions for your operation.
Many of our customers are working diligently to make their operations more sustainable. They choose Chem-Trend because we’ve been focused on minimizing the environmental impact of our products since we began. We developed the first commercially viable water-based die lubricant in the 1960s, which had an immensely positive impact on the health and safety aspects of die cast facilities by removing the use of graphite and/or solvents in the die lubricants that were widely used at that time. Continual efforts extend to a variety of other environmental impact concerns, including the use of VOCs in solvent-based mold release agents. Today Chem-Trend leads the industry in the development of innovative solutions.
Are there any consequences of applying an excessive amount of release agent?
When an excessive amount of release agent is applied, it can lead to difficulties in the subsequent treatment of the moulded parts. This is because the excess release agent can create a surface on the moulded part that is oily or slick in nature.
How should the mold release agent be applied?
The application methodology for mold release agents varies depending on the carrier, release agent characteristics, process, and process environment. The application technique plays a crucial role and can significantly impact the performance of the release agent. Here are some common application methods:
1. Spray Gun Application: In most cases, release agents are applied using a spray gun, either manually or through robot application. Programmable spray systems with multiple spray nozzles are also utilized to apply one or more release agents. Nozzle size is regulated to ensure proper atomization, considering factors such as expected throughput and release agent viscosity.
2. Air Assisted and Airless Spray: Spray application can be air assisted, where air is used to further shear and atomize droplets, or airless, where the nozzle operates at high pressure to shear the release agent stream for atomization. These methods ensure effective coating and film formation.
3. Electrostatic Spray Guns: Solid and liquid release agents can be applied using electrostatic spray guns, which utilize an electrical charge to enhance the adhesion and coverage of the release agent.
4. Aerosol or Wiping Application: Depending on the specific application, release agents can also be applied through aerosols or by manual and automated wiping techniques.
It is important to select the appropriate application method based on the specific requirements of your mold release agent and process. Consider factors such as viscosity, atomization, throughput, and desired film formation. By employing the right application technique, you can enhance the performance and efficiency of the mold release agent, leading to improved mold release, reduced defects, and enhanced productivity. Experiment with different application methods to find the optimal approach that best suits your needs. Always follow the manufacturer’s instructions and consider any safety precautions associated with the chosen application method.
What are the main functions of a mould release agent?
Mould release agents serve multiple important functions in the moulding process. Firstly, they create a physical and/or chemical barrier that separates the material being moulded from the surface of the mould. This barrier ensures easy separation of the moulded material from the mould surface.
Additionally, mould release agents impact various process characteristics. They can influence the flow rate of the material within the mould cavity, the overall moulding cycle time, and the ease of release. The choice of mould release agents also affects the finish characteristics of the released part, including factors like gloss level and accurate texture reproduction. Furthermore, mould release agents play a role in post-molding operations such as adhesion or coating of the moulded part.
Moreover, the selection of mould release agents can influence the lifespan of the mould between maintenance cycles and contribute to overall productivity. By considering these factors, mould release agents contribute significantly to the successful outcome of the moulding process.
What is the recommended dilution ratio for optimal results?
The optimal dilution ratio is not a fixed value as it varies depending on the specific machine and application. To achieve the best outcomes, it is crucial to determine the appropriate dilution ratio that ensures an adequate lubricant film is formed in the shortest spray time feasible.
What types of mold release agents carry out these functions?
Mold release agents can be classified into different categories based on their carriers and their interactions with the molding process. Here are some examples:
1. Based on the type of carrier:
* Solvent-based release agents: These formulations dissolve or disperse the active principles of the release agent in a solvent or blend of solvents. Solvent choice influences dispersion quality, film formation, and evaporation rate. They can be used in both heated molds and at room temperature.
* Water-based release agents: The active components of these release agents are emulsified into water since they are generally not water-soluble. This category is more environmentally friendly with reduced or no VOCs (volatile organic compounds). They require stable emulsion and good film formation, especially at room temperature. Dilution is often possible.
* Carrier-free release agents: These solid release agents are typically in powder form and are applied using electrostatic spray guns. Film formation occurs upon contact with the heated surface, similar to powder coatings.
2. Based on how the mold release agent (MRA) interacts with the process:
* Sacrificial Release Agents: Applied in every molding cycle, these release agents form a film on the mold surface that depletes after each cycle and needs replenishment.
* Semi-Permanent Release Agents: These reactive release agents chemically adhere to the mold surface, providing a release barrier while allowing for multiple molding cycles before reapplication is necessary.
* Internal Mold Release Agents: Specialty chemicals embedded into the material being molded, these agents are chemically incompatible and migrate to the surface during the molding process, forming a release layer. Heat can accelerate the release agent migration mechanism.
Understanding the different types of mold release agents and their functions is essential for selecting the appropriate formulation for your specific application. Consult with industry experts or suppliers to determine the best mold release agent for your needs, considering factors such as mold material, part complexity, release requirements, and production environment.
By utilizing the right mold release agents, you can enhance mold release performance, optimize production cycles, and ensure the production of high-quality molded parts.