Männer Molding Solutions | intelliGate-p

intelliGate-p bietet die Vorteile der Kavitätsdrucküberwachung – ohne einen Sensor in der Kavität zu installieren.

Das System liefert während des gesamten Spritzgießprozesses hochpräzise Echtzeitmessungen des Kavitäts- und Anspritzdrucks und erzielt dabei Ergebnisse, die mit denen konventioneller Kavitätsdrucksensoren vergleichbar sind.

intelliGate-p ermöglicht die frühzeitige Erkennung von Prozessabweichungen, unterstützt eine stabile und reproduzierbare Produktion, gewährleistet eine konstante Bauteilqualität und trägt dazu bei, Ausschuss zu reduzieren und kostspielige Stillstandszeiten zu vermeiden.

Kein Einfluss auf das Werkzeugdesign

Sensoren sind in das Heißkanalsystem integriert, nicht in das Werkzeug.
Prozessüberwachung für Multikavitäten-Anwendungen

zur Erkennung von Ungleichgewichten, unvollständig gefüllten und überpackten Bauteilen.
Prozessregelung durch automatische Umschaltung

basierend auf einem erkannten Kavitätsdruckniveau.
Unterstützt Predictive Maintenance

durch die Erkennung von klemmenden Ventilnadeln oder verschlissenen Aktuatordichtungen anhand von Veränderungen im Bewegungsverhalten der Ventilnadel.

Vergessen Sie komplexe Sensortechnik in den Kavitäten.

Ersetzen Sie einfach den Standard-Nadelhalter in Ihrem Heißkanalsystem durch den neuen IntelliGate-p Nadelhalter mit integriertem Drucksensor – für eine zuverlässige Kavitätsdrucküberwachung ohne Sensoren im Werkzeug.

Rüsten Sie Ihr bestehendes Männer Nadelverschlusssystem auf oder nach.

Alle Männer Heißkanalsysteme mit pneumatischer PS 48.2 Betätigung können nachgerüstet werden. Die Nachrüstung lässt sich einfach in bestehende Werkzeuge integrieren, ohne dass konstruktive Änderungen erforderlich sind.

Intelligate P, reliable cavity pressure data without mold changes

Simplify the Process, Enhance Control

Traditional cavity pressure sensing often adds unnecessary complexity to mold design and installation, requiring sensor bores, additional wiring, and precise machining that increase both cost and risk. Limited mold space can further compromise ideal sensor placement.

Because sensor positions vary from mold to mold, pressure data frequently needs mold-specific interpretation, making process transfer, benchmarking, and setup more time-consuming.

IntelliGate P removes this complexity by integrating the piezoelectric pressure sensing principle directly into the pin holder. This eliminates the need to install a sensor inside the mold and allows the system to be implemented using a standard screw connection in the pneumatic interface.

What You Can Expect with IntelliGate P

Ready for New Systems and Retrofit

IntelliGate P is designed for seamless integration in both new hot runner systems and retrofit applications. Existing PS 48.2 setups can often be upgraded without changing the pneumatic plate, reducing downtime and investment effort.
Fast, Service-Friendly Replacement

The modular design allows fast replacement of the piston, pin, sensor cable, and insulating plate. Maintenance becomes easier, faster, and less risky compared to conventional cavity sensor solutions.
Injection Monitoring with Matching Signal Behavior

During the injection phase, IntelliGate P reproduces the same pressure curve characteristics as conventional cavity pressure sensors, enabling reliable process monitoring without changing molding results.
Consistent Data Interpretation Across All Molds

Because the sensor position is always identical in the pin holder, signal interpretation remains consistent across molds. This simplifies benchmarking, process transfer, and setup optimization.

Connectivity Options

With Injection Molding Machine
With Priamus
With External Products

We offer the right refurbishment package –
tailored to your mold's needs.

Whether your mold requires only minor adjustments or a full mechanical and functional overhaul: we offer a flexible range of refurbishment solutions to match your goals, timeline, and budget. All packages are carried out by experienced tooling experts using OEM-level standards and documentation. Planned refurbishment reduces unexpected downtime, lowers total cost of ownership, and keeps your production running efficiently.

Mold Refurbishment Light Package
Our Light Package focuses on essential components to restore reliable performance with minimal downtime:

Full refurbishment of the hot runner system

Replacement of guiding and centering elements for FH & MH (AS & DS)

Warranty renewal of the hot runner system in accordance with Otto Männer GmbH’s general terms and conditions

This package is ideal for molds still in good condition that require targeted maintenance to ensure consistent part quality and continued process stability.
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Mold Refurbishment Full Package
Our most comprehensive package restores your mold to peak performance – ideal for extending lifecycle and maximizing output reliability:

Complete replacement of cavity stacks

New guiding and centering elements

Replacement of all wear and tear parts

Full cleaning and inspection of the entire mold

Final Operational Test (FOT) to validate performance

Warranty renewal with 50% of the original new mold conditions – minimum 1 million cycles guaranteed

This package is recommended when a mold shows extensive wear or reduced precision. It offers a cost-efficient alternative to new mold investment, with high functional reliability.
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Mold Refurbishment Custom Package
Tailored refurbishment after a comprehensive mold assessment – based on the exact condition and requirements of your mold.

On-site assessment by our experts

Customized quotation based on actual wear and condition

Refurbishment performed at the MS mold plant, using OEM standards

Final Operational Test (FOT) ensures mold readiness

Warranty renewal after full refurbishment with 50% of the original warranty conditions – minimum 1 million cycles

Cost transparency & value-added:

Refurbishment > €100k → 50% reimbursement of the assessment costs

Refurbishment > €200k → 75% reimbursement of the assessment costs

Optional add-ons:

Spare parts packages (mold / hot runner)

Stand-alone repairs of damaged components (if feasible)

Modifications to meet new production or product requirements

This package is ideal for complex, high-value molds where a detailed condition-based approach ensures maximum return on investment.
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Cube Mold Refurbishment ETW Package

Planned hot runner maintenance can reduce downtime by up to 70%.

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Mold & Hot Runner Refurbishment Spare Parts Agreement
Always Ready, Always Reliable: A spare parts agreement with Männer or Foboha ensures that essential components are always available to keep your molds running smoothly. By securing predefined parts in advance, you minimize downtime and increase efficiency.

Your benefits at a glance:

Rapid availability
Immediate access to critical spare parts – less unplanned downtime, better service performance.

Cost efficiency
Attractive long-term conditions and pricing through fixed contracts.

Planning reliability
Simplified scheduling of maintenance and repairs with assured parts supply.

Lower administrative effort
Reduce time and resources needed for sourcing and procurement

Storage costs are covered by Männer/Foboha
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Everything You Need, All The Benefits

No Mold Design Modifications

Sensor integration inside the hot runner eliminates mold rework and redesign.
Automatic Process Control

Automatic switchover triggered by detected cavity pressure levels.
Consistent part quality

Detect process deviations early and maintain stable production.
Easy retrofit

Upgrade existing Männer PS 48.2 systems without redesigning molds.
Predictive Maintenance

Detect valve pin sticking and actuator seal wear before failures occur.
Reduced Downtime

Identify issues early and plan maintenance proactively.
No Witness Marks

Eliminate marks caused by cavity-mounted pressure sensors.
Open Connectivity

Compatible with Priamus FillControl and third-party monitoring solutions.