Mold Maintenance and Repair: A Case from the KVOTA Team

Reliable tooling and timely technical maintenance—especially when it comes to complex molds with hot runner systems (HRS) – are core factors of successful manufacturing.

Time from time some molds require not just preventive maintenance but comprehensive repairs, including geometry restoration, EDM and milling work, and the repair of heating elements, cooling systems, and other components.

Case Executed by the KVOTA Team:

Object: 8-cavity hot runner mold for injection molding of a housing part made of ABS plastic

Dimensions: 800×800×750 mm
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The Problem:

• Plastic leakage inside the mold
• Complete flooding of all internal components with plastic
• Damage to nozzles, thermocouples, and Pin 24 connectors
• Deformation of mounting locations
• Complete absence of technical documentation
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Diagnosis:

A factory defect in the hot runner system — the nozzle's fitting diameter did not match the hole in the plate, which caused play and deformation of the mold structure.
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KVOTA’s Solution:

• Removal of solidified plastic
• Full preventive maintenance using Ambersil lubricants
• Replacement of nozzles, thermocouples, heaters, and restoration of ceramic components
• Burning of mounting seats using copper electrodes (EDM treatment)
• Restoration of mold geometry, including cooling system elements
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Result:
Since April, the mold has completed over 500,000 cycles—without a single failure.

More photos available in the section: Photos of Our Molds and Dies.

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Our team once again proved that quality service, expertise, and trusted solutions ensure consistent tooling performance.