DF Gold Series

In celebration of our approaching 50th year "Golden" anniversary, INCOE® introduces the DF Gold Series hot runner system. Based upon the previous generation of proven and reliable hot runner technology (the DF Series), the DF Gold series is an innovative refinement of the technology providing increased hot runner performance and robustness while maximizing molder up-time.
DF Gold Series improvements include:
Twin Heater – The Twin Heater incorporates two separate heating circuits in each nozzle heater. This redundancy provides for uninterrupted production if a single heater circuit failure should occur and allows for easy replacement during a planned maintenance period. A second heater thermocouple can also be added to provide another level of redundancy to the system. Heater dimensions remain consistent compared to the previous generation heater, allowing for simple upgrades for previous generation hot runner systems.
Gating Configurations – Several new tip designs have been added for increased flexibility for application solutions. All tips utilize a proprietary coating that yields increased wear resistance.
Color Seal – A final solution for troublesome color change issues. Often color change can simply be performed by increasing melt temperature while purging the system. However with some materials the color to be removed often can stay within the gate well area and continue to “bleed” through to the new color, creating defective molded parts. The introduction of the new Color Seal traps the material and can easily be removed between color changes.
Ceramic Manifold Insulation – Utilization of ceramic supports in DF Gold systems allows for a significant decrease in heat transfer from the system to the mold, reducing energy consumption and increasing thermal consistency across the melt delivery system.
Opti-Flo™

Beaumont Technologies Inc. and INCOE® introduce the first hot runner utilizing BTI's patented MeltFlipper® melt rotation technology. INCOE® and BTI's Opti-Flo™ design, incorporated in select INCOE® manifolds, is the first scientifically designed hot runner system providing a homogeneous melt distribution and balanced filling to and across all cavities while avoiding invasive and restrictive mixers. The Opti-Flo™ system also replaces the common practice of creating melt temperature variations in the nozzles to balance cavity filling. The result is improved cavity to cavity consistency and product quality.
Valve Gating

DF Valve Gate systems are offered for both hydraulic and pneumatic actuation. The robust and compact cylinder design allows closer centers and consistent repeatability. Both the hydraulic and pneumatic versions of the actuation cylinders mount directly onto the manifold. This feature makes it unnecessary to remove the valve pins before removing the entire system from the mold. This feature also allows INCOE® DFQ hydraulic Valve Gate systems to be supplied as a completely self-contained unit, both pre-plumbed and pre-wired.
Pneumatic DF Valve Gate systems are ideal for clean room molding applications such as medical disposables. Zero gate vestige is usually mandatory, and the pneumatic actuation allows consistent and rapid closing of the valve pin, complimenting part weight and dimension requirements.
DF Valve Gate Performance Features:
zero gate vestige
cycle time reduction by fast filling and only partial use of hold pressure
no freezing, stringing or drooling of gates at start up or interruptions
low melt stress and low part distortion
elimination of weld lines when used with Gate Sequence Control (GSC)
elimination of folds in back-molding applications with GSC
balanced filling of different size parts in family molds
DSV Single Valve Gate
The new style DSV is a modular design using proven standard components, optimizing function, reliability, and service. Melt flow orientation and temperature profile is optimized, improving gate and molded part quality. The new DSV can be operated pneumatically or hydraulically. Options include mounted electric and/or pneumatic / hydraulic connections. The DSV offers 3 flow sizes; 8, 12 and 18 mm and nozzle lengths up to 250 mm for small to high shot weight and difficult processing resins.
Back-to-Back Valve Gate
Compact yet functional designs are a necessity for stack mold applications. Common valve gate designs require the cylinders that operate the valve gate to be off-set in order to reduce stack height dimensions. Still this design generally results in larger molds and perhaps injection molding machine size. INCOE®'s new back-to-back design eliminates the offset requirement while making no compromise in stack height and presents the potential for cost savings in mold construction.
DF3 Micro Series

INCOE®'s DF3 Micro Series hot runner systems are designed for small part molds utilizing very high cavitation common in the pharmaceutical, medical, and packaging markets. DF3 Micro nozzles are secured to the manifold with a minimal pitch design of 19 mm.
Integrated/Unitized

DFQ nozzles have the advantage of threading directly into the manifold to provide a leak-proof connection. Because the system can already be supplied as an assembled unit, it also allows the system to be supplied pre-wired, or Unitized. Encased in stainless steel channels, the heater leads are protected during assembly into the mold. Designed and built to customer specification, the Unitzed Hot Runner system is ready to drop into the mold and begin sampling. The Unitized concept eliminates the need for a costly injection half, since the hot runner is already pre-wired and self contained.
DF hydraulic valve gate actuation cylinders are unique in that they mount directly onto the manifold. Combined with the unitized concept for a thermal gate system, the hydraulic and water lines can be pre-piped to an attached plate where quick connect fittings are located. Thus, like the electrical wiring, the hydraulic and water piping is self contained. Installation or removal of the system for routine maintenance now can be accomplished in much less time, increasing machine productivity and your bottom line.
Injection Half Hot Runner Systems

It is common for mold manufacturers to desire complete hot half hot runner systems in order to reduce their overall delivery time by eliminating the assembly of a standard hot runner system within their mold. INCOE® hot halves are fully operational, assembled units wired and pre-tested for functionality prior to leaving the INCOE® factory. INCOE® hot halves are ready for assembly to the cavity plate at the mold manufacturer, reducing initial mold trial test time.
Control Gate

Valve gate systems offer injection molders the optimal performance when using hot runner molds, yet the vast majority of hot runner systems sold are thermally operated. Generally the reason for the selection of thermal gate vs valve gate operation is purely cost.
INCOE® now offers a solution that offers the advantage of predictable consistent gate opening found in valve gates at a price nearer to that of a comparable thermal gate system.
Control Gates can also achieve the cycle saving advantage over thermally operated systems and can be used to eliminate drool when using a vertical injection molding machine in the same way as a more expensive fully operated valve gate system.
When optimal gate performance or sequential operation is the outstanding criteria; a full Valve Gate system is still necessary. However, when the selection is mainly focused on the operation of predictable gate opening/closing the Control Gate offers our customers the opportunity of substantial savings.
Edge Gate

For the production of most cylindrical tube type molded parts the mold design dictates a side or edge gate style nozzle. INCOE® is proud to introduce an edge gate product that incorporates design features taken from our proven DF product line.
INCOE®'s Edge Gate nozzle also incorporates some of the new features from the new DF Gold nozzle series, including Twin Heater technology, coated tips for extended wear, and utilization of the Color Seal.
Multi-Tip

INCOE®'s Multi-Tip solutions offer an economical solution for high cavitation molds when using materials that are not demanding. Molded part dimensions for some unique shaped parts, that previously may have required a hot to cold runner design, can now also be fully hot runner.
The larger Multi-Tip solution, the DMT-5, can have 2 points as close as 13mm, and up to 6 points on a 26mm circle.
The new DFT-3 Micro Multi-Tip offers 2 points as close as 6mm, and up to 6 points on a 12mm circle.
Multi-Pin

Typical valve gate designs require large pitch dimensions in order to accommodate the cylinder device that operates the open/close action of the valve gate. INCOE®'s new Multi-Pin Valve Gate provides for up to four pins contained within a single cylinder mechanism easily accommodating small dimensioned molded parts. As molds can then be manufactured in a more compact size cost savings are realized.
Multi-Component

Market demands in a variety of products ranging from automotive to packaging have created a multi-material specialty in injection molding. Molds for the production of these molded products are complex, and therefore so are the demands and design of the hot runner system. INCOE® meets these requirements by providing angular manifolds when needed, and various combinations of thermal and valve gate operation as the application demands.
As the processing of the material used in the same mold can be diverse, INCOE®'s DF Gold Series design offeres precise melt control with features such as Twin Heater profiled nozzle heaters. Both pneumatic and hydraulic valve gate are available when flow sequencing or cosmetic concerns are required for the application.
DFS Standard Manifolds

INCOE®'s DFS Standard Manifolds are pre-manufactured up to a certain point and await final customer dimensions for finishing. This flexibility allows common sizes to be supplied rapidly for quick delivery.
DFS systems are delivered completely assembled. Separate parts, adjustments, and hold down screws are not necessary.
Three DF series are available for 2-drop and 4-drop systems.
2-Drop Inline Systems:
DFQ-5: Nozzle to Nozzle 100-250mm
DFQ-8: Nozzle to Nozzle 150-300mm
DFQ-12: Nozzle to Nozzle 150-300mm
4-Drop X-Pattern Systems:
DFQ-5-X: Symmetrical x and y dim. 35-89mm from (0,0) on 45°
DFQ-8-X: Symmetrical x and y dim. 35-89mm from (0,0) on 45°
DFQ-12-X: Symmetrical x and y dim. 53-107mm from (0,0) on 45°
Temperature Controls

M-Series Temperature Control
The M-Series hot runner temperature controller offers technology second to none, such as the continuous self-tuning feature. The M-Series control utilizes the well known Windows architecture, making operation of the control easy to learn and use. Operator input can be achieved by touch screen PC or Lap Top; and is also equipped with a keypad in the event of computer failure the operator maintains the ability for input. The control is modular in construction offering 16 to 128 zones as standard.
Microcom II Temperature Control
The Microcom II Temperature Control offers precision control of INCOE® Hot Runner systems for an inexpensive price. This control features Phase Angle Fire output to prolong heater life, while Zero Crossing output is also available if required. Other features include; Soft Start, Alternate Set Point, High and Low Alarm, F/C switch, and more. The Mircrocom II can be supplied in complete enclosure packages from 1 to 48 zones. To replace a single zone, just slide the module out and replace it with a new zone.
Valve Gate Sequencing

Market demands for injection molded parts requiring complex geometries, superior surface quality or decorative appliqués that tend to be more difficult to fill causing a variety of molding challenges. Injection fill of multi-cavity or multi-gated single cavity molds can be manipulated using hot runner valve gate systems with Valve Gate Control. INCOE®'s GSC2™ Gate Sequence Control patented technology provides injection molders optimum control of the most demanding applications. Precise and repeatable valve gate pin opening and closing can be accomplished by volume, cavity pressure or time.
Benefits of GSC2™:
Weld Line Positioning or Elimination
Consistent Part Weights in Family Molds
Clamp Force Reduction
Reduction of Warpage or Flash from Over-packing
Superior Surface Quality for in In-Mold Decorating and Painted or Chromed Parts

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