Patented Technology

Advanced Monitoring

Real-Time Control

Melt-IQ^™

Real-Time Melt Temperature Monitoring

Good/Bad Part Quality Detection

VP Switch Point Control

Price Price Available on Request

Worldwide Shipping

Installation Support

Patented Technologies, Advanced Monitoring, Real-Time Control

Technical Specifications at a Glance

Complete technical details of the Melt-IQ™ for comprehensive process monitoring and control.

PARAMETER

SPECIFICATION

Processor

Powerful 24-bit ADC microchip processor

Power Supply

120-230V -5V power supply

Inputs

Five (5) digital type K thermocouple inputs

Enclosure

Industrial 10x8x8 enclosure

Board

Proprietary embedded board with 24bit precision ADC

Display

HMI display

Sensor Placement

Placed into the distal end of the injection molding machine's end cap, nozzle cylinder, or last to fill cavity

Country of Origin

🇺🇸 United States

Advanced Math Modeling & Control Logic

Proprietary algorithms that transform raw melt data into intelligent process decisions — enabling unmatched shot control and real-time quality prediction.

Learn the Work & Thermal Mass Density

The Melt-IQ™ is the first system of its kind to "Learn the Work" imparted into the polymer. Using high-speed ADC and proprietary math models, it calculates Thermal Mass Density to define shot weight with unprecedented accuracy — turning any IMM into a Decoupled II Phenom.

3 Critical Quality Variables

During the Fill Stage, the system analyzes Max Te (peak temperature), Power Factor (PF) (area under the integral), and Viscosity Rise (VR) (integral from injection start to Te). Statistical analysis of these variables sets alarm windows to determine Good/Bad part production with incredible accuracy.

Intelligent V-P Switch Control

By learning the work integral (F1) and time to reach the integral (F1T), the Melt-IQ™ bypasses the machine's native position/time sensors. A digital relay and mechanical toggle execute the switch, giving complete control of the fill stage to the Melt-IQ™ for superior part consistency.

Dual-Mode Intelligence

In Monitor Mode, the system learns applied work and statistically analyzes data for future alarm setup. In Control Mode, it actively manages the V-P switch point — a breakthrough that makes injection molding processes fundamentally better.

DON'T JUST TAKE OUR WORD WATCH TO SEE HOW IT WORKS

Engineered for Superior Process Control

Transform your injection molding operation with advanced monitoring and control capabilities that ensure consistent quality and reduce waste.

Real-Time Temperature

Monitor melt temperature in real-time during the injection molding process, ensuring optimal processing conditions and consistent part quality through continuous temperature measurement and analysis.

Mass Displacement Control

Precisely measure mass displacement for each shot, providing accurate control over material flow and ensuring consistent fill patterns for uniform part dimensions and weight.

Quality Prediction

Advanced algorithms predict good or bad parts before completion, enabling proactive process adjustments and reducing scrap rates while maintaining high quality standards.

VP Switch Control

Controls the velocity-pressure switch point during injection forward phase, optimizing the molding process for improved part consistency and reduced cycle times.

Process Stability

Monitor and analyze process stability and consistency, detecting variations in polymer viscosity and thermal-mechanical energy to ensure repeatable manufacturing results.

Advanced Processing

Powered by a proprietary embedded board with 24-bit precision ADC and powerful microchip processor, delivering accurate measurements and reliable performance in industrial environments.

Frequently Asked Questions

How does the Melt-IQ™ improve injection molding quality?

The Melt-IQ^™ monitors real-time melt temperature, measures mass displacement for each shot, and uses advanced algorithms to predict good or bad parts before completion. This enables proactive adjustments and significantly reduces scrap rates while ensuring consistent quality.

What is the VP switch point control feature?

The VP switch point control manages the velocity-pressure transition during the injection forward phase. This optimization ensures better part consistency, reduces cycle times, and improves overall molding process efficiency by precisely controlling when the injection switches from velocity to pressure control.

Where is the Temp-Sense™ sensor installed?

The micro-bead Temp-Sense^™ sensor is placed into the distal end of the injection molding machine's end cap, nozzle cylinder, or last to fill cavity. This strategic placement ensures accurate melt temperature readings at critical points in the process.

What power requirements does the system have?

The Melt-IQ^™ comes with its own 120-230V -5V power supply and is housed in an industrial 10x8x8 enclosure. It features five digital type K thermocouple inputs and includes an HMI display for user interface and monitoring.

Are software upgrades included with the system?

Yes, the Melt-IQ^™ includes free software upgrades to ensure your system stays current with the latest features and improvements. Md Plastics continuously enhances the system's capabilities and provides these updates at no additional cost.

Industries We Serve

Serving diverse sectors with specialized plasticating solutions for enhanced manufacturing performance.

Automotive

Precision plasticating solutions for high-quality automotive components requiring consistent melt quality and performance.

Medical Devices

Advanced plasticating technology ensuring purity and precision for critical medical device manufacturing applications.

Consumer Electronics

Innovative solutions for complex electronic housings and components requiring superior surface finish and dimensional accuracy.

Additive Manufacturing

Specialized plasticating systems for 3D printing and additive manufacturing, delivering consistent filament quality and material flow.

Plastic Processing

Comprehensive plasticating solutions for general plastic processing applications across various manufacturing sectors.