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                                                                betwinner bet 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.

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                                                                                We offer a broad portfolio of conventional (apply-every-cycle) mold release agents to meet the needs of our customers. Our conventional (sacrificial) mold release agents are:

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                                                                                    • Available water-based or solvent-based
                                                                                    • Formulated as ready-to-use or dilutable, depending on the application
                                                                                    • Suitable for multiple types of spray equipment
                                                                                    • Capable of “tailored” dilution rates, depending upon the application and amount of slip required
                                                                                    • Excellent for molded parts with very complex geometry
                                                                                    • Exceptionally low in in-mold buildup/mold fouling

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                                                                                    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:

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                                                                                            • 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

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                                                                                                Always on the cusp on innovation and sustainability, betwinner-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

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                                                                                                        • 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.

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                                                                                                                              betwinner-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.

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                                                                                                                                  • Many of our customers are working diligently to make their operations more sustainable. They choose betwinner-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 betwinner-Trend leads the industry in the development of innovative solutions.

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                                                                                                                                                                  Looking for answers about release agents for thermoplastics processing applications? Learn more about frequently asked questions and the answers you need.

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                                                                                                                                                                            Can mold release agents cause problems in post molding treatments?

                                                                                                                                                                            In general, post mold treatment of surfaces can be adversely affected by the residual presence of release agents if the release agent is not compatible with such treatment or if it is present in excess on the released part surface. The choice of release agent chemistries compatible with post release operations, the adjustment of the application level onto the mold and the choice for low transferring release agents (like semi-permanent ones) can lead to successful post molding operations and minimize any part contamination issues.

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                                                                                                                                                                                        How do the specific applications (composite, plastic, rubber, etc.) affect the type of mold release agent recommended?

                                                                                                                                                                                            In general, the release agent should not be chemically compatible with the material being molded: offering a good chemical and physical barrier preventing the molded compound from chemically interacting with the mold (substrate). It is the old adage “like dissolves like”, so if the release agent and material are too compatible, the material can penetrate the release agent film and adhere to the mold surface. The composition of the material being molded, as well physical characteristics like hardness and abrasion (often influenced by fillers and reinforcing agents), influence the choice of release agent. Different metal alloys, thermosets, thermoplastics and elastomeric materials have different molding processes and conditions which demand different requirements from the release agent, affecting mold release selection.

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                                                                                                                                                                                                    How rapidly is the industry moving away from solvent based mold release agents and towards water based mold release agents?

                                                                                                                                                                                                      The shift greatly depends on the industry and process requirements. Several industries no longer tolerate solvent-based products due to health, safety and environment concerns or other regulatory issues. Industries such as die casting, tire manufacturing, and general rubber molding use predominantly water based release agents. The polyurethane industry uses both water based and solvent based mold release agents, the composites and thermoplastics industries use mostly solvent based release agents at this time.

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                                                                                                                                                                                                          • Water-based products are more sensitive to application (offering more challenges to film formation) and have slower evaporation rates (which can be influenced by the application method, process conditions and environment humidity levels) than solvent based products. Water-based products are more prone to cause chemical interaction of residual water remaining on the mold surface with the material being molded during the molding process (e.g. generation of urea byproducts in polyurethane molding). This category of release agents also requires more technology to ensure emulsion stability and bio-activity resistance. These challenges have to be addresses to expand the use of water based release agents across a wider range of industries.

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                                                                                                                                                                                                                How should non-aerosol release agent products be applied in thermoplastic processing operations?

                                                                                                                                                                                                                  Non-aerosol products are best applied in thermoplastic processing using a high quality spray gun or with clock-controlled spraying equipment.

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                                                                                                                                                                                                                              How should the mold release agent applied?

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                                                                                                                                                                                                                              Application methodology depends on the carrier of choice as well as on the nature of the release agent and the process and process environment. Application is a key aspect to be observed and may significantly influence the performance of the release agent. In most cases, release agents are applied using a spray gun (manual or robot application). In some applications programmable spray systems with multiple spray nozzles allowing for the application of one or more release agents are used. The nozzle size is regulated to ensure proper atomization (influenced by the expected throughput and release agent viscosity) and good film formation. Spray application can be air assisted (where air is used to further shear and atomize droplets) or airless (where the nozzle operating at high pressure shears the release agent stream to obtain the necessary atomization). Electrostatic spray guns can also be used to apply solid and liquid release agents. In some applications, release agents can also be applied by aerosols or even through manual or automated wiping.

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                                                                                                                                                                                                                                            What are the advantages and disadvantages of each type of release agent?

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                                                                                                                                                                                                                                                Each type of agent has its own particular strengths (S) and limitations (L). Here is a brief overview by type of release agent:

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                                                                                                                                                                                                                                                  • Solvent-based release agents:
                                                                                                                                                                                                                                                    • S: Easier to apply. The solvent carrier also helps with the film formation. The evaporation rate can be adjusted based on the solvent blend. The choice of solvent may ease the dissolution / dispersion of the release agent active ingredients.
                                                                                                                                                                                                                                                    • L: Not highly environmentally friendly. Offer higher health (VOC’s) and safety concerns (fire hazards) than non-solvent based products.
                                                                                                                                                                                                                                                  • Water-based release agents:
                                                                                                                                                                                                                                                    • S: Environmentally friendly and presents no fire hazards. May sometimes be dilutable (can be shipped as concentrates). They can be used to cool the die if necessary. May be developed with a level of technology that ensures mold release agent performance equivalent with solvent based release agents.
                                                                                                                                                                                                                                                    • L: Require more complex technology to manufacture. Proper film formation can be more challenging. This category of release agents may be more prone to stability issues and biological attack. Water-based release agents have slower evaporation rates than their solvent based counterparts and may not be appropriate for some room temperature molding operations or operations with short cycle times. Residual water onto the mold may affect molding performance (entrapped steam) or even chemically react with the material being molded. The latter is particularly an issue when molding polyurethane parts.
                                                                                                                                                                                                                                                  • Carrier-free betwinner bet Agents:
                                                                                                                                                                                                                                                    • S: Can be applied “as is” due to the absence of carrier. No vapors emission. Less noisy application is observed. Do not require dilution or tank storage. No waste stream.
                                                                                                                                                                                                                                                    • L: Can create a dust hazard if not applied properly. Require special application equipment (often being electrostatic spray guns), which may require expensive investment. The use of carrier-free release agents may also require additional modifications to the molding equipment to ensure thermal balancing of the mold. These factors often limit the application of this category of release agents.
                                                                                                                                                                                                                                                  • Sacrificial betwinner bet Agents:
                                                                                                                                                                                                                                                    • S: Easy to apply. Require less application technique and offer more tolerance of work (less dependent on trained operators).
                                                                                                                                                                                                                                                    • L: Tend to build up on the mold if over applied. In general, the release coating is partly transferred to the molded part, which may cause negative side effects on post molding operations (painting, adhesion, etc.) if applied in excess or if the release agent chemistry is not compatible with the post molding operation. If water-based, tend to cool the mold, removing heat & energy from the system (this may represent a disadvantage if the process is not designed for that).
                                                                                                                                                                                                                                                  • Semi-Permanent betwinner bet Agents:
                                                                                                                                                                                                                                                    • S: Require significantly lower application frequency than sacrificial release agents because the release agent film lasts for multiple molding cycles (frequency depends on the process conditions). Allow for a more steady and continued production without interruption for release agent application. There is very little transfer to the molded part, which allows for better post molding operations (coating, adhesion). The release agent can be reapplied regularly on the coated mold refreshing the release agent film. This category of release agents provides an excellent combination of chemical and physical barriers, preventing build up and providing the desired release performance.
                                                                                                                                                                                                                                                    • L: Requires more training of operators to ensure the right touch up frequency is observed. Molds need to be clean to allow for good interaction between the release agent and the mold surface during the initial application of the release agent.
                                                                                                                                                                                                                                                  • Internal Mold betwinner bet Agents:
                                                                                                                                                                                                                                                    • S: Reduce the need for external mold release agents.
                                                                                                                                                                                                                                                    • L: May continue to exude to the surface over time compromising post molding operations (coating and adhesion) or the surface cosmetics of the part. Often do not eliminate the need for external releasants as the internal mold release agents do not always migrate to the mold interface or may not ensure 100% release efficiency. Limited in their capability of performing high performance release agent functions such as affecting part surface characteristics.
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                                                                                                                                                                                                                                                3. What are the advantages and disadvantages of silicone-free versus silicone-containing release agents?

                                                                                                                                                                                                                                                4. The advantage of silicone-containing release agents is that they offer a very good release effect. The disadvantage of silicone-containing release agents is that the subsequent treatment of the released parts, such as gluing or painting, may be difficult or even impossible. Additional post molding part processing will be required.

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                                                                                                                                                                                                                                                    What are the main functions of a mold release agent?

                                                                                                                                                                                                                                                    Mold release agents provide not only a physical and/or chemical barrier as the means of separation between the material being molded and the mold surface, but also impact process characteristics like the flow rate of the material being molded within the mold cavity, molding cycle time and, of course, release ease. The choice of mold release agents also affects finish characteristics of the released part like gloss level, accurate texture reproduction, post molding operations (e.g. adhesion or coating of the molded part) in addition to influencing the mold service life in between maintenance cycles, and overall productivity.

                                                                                                                                                                                                                                                              What factors need to be considered in selecting a mold release agent?

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                                                                                                                                                                                                                                                              Factors to be considered for selecting the proper release agent include:

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                                                                                                                                                                                                                                                                • Mold material / substrate
                                                                                                                                                                                                                                                                • Material being molded
                                                                                                                                                                                                                                                                • Process conditions:
                                                                                                                                                                                                                                                                  • Temperature
                                                                                                                                                                                                                                                                  • Line speed / cycle time
                                                                                                                                                                                                                                                                  • Pressure
                                                                                                                                                                                                                                                                  • Specific molding process such as injection molding, high pressure, gravity fill, compression, etc.
                                                                                                                                                                                                                                                                  • Process variable fluctuations
                                                                                                                                                                                                                                                                • Geometry of the mold
                                                                                                                                                                                                                                                                • Post molding operations (adhesion, coating)
                                                                                                                                                                                                                                                                • Expected performance level and productivity (number of good releases or good parts demolded per time period)
                                                                                                                                                                                                                                                                • Existing process issues (cavity filling challenges, soldering, release-related scrap rates, process condition fluctuations etc.)
                                                                                                                                                                                                                                                                • Mold maintenance expectations (mold cleaning frequency)
                                                                                                                                                                                                                                                                • Part finish requirements (gloss, marring, etc.)
                                                                                                                                                                                                                                                                • Application methodology
                                                                                                                                                                                                                                                                • Health Safety and Environmental (HSE) requirements