Männer Molding Solutions | intelliGate-p

intelliGate-p offre tutti i vantaggi del monitoraggio della pressione in cavità, senza richiedere l'installazione di sensori all'interno dello stampo.

Il sistema fornisce misurazioni altamente precise e in tempo reale della pressione in cavità e in corrispondenza del punto di iniezione durante l’intero processo di stampaggio a iniezione, con risultati paragonabili a quelli dei tradizionali sensori di pressione in cavità.

intelliGate-p consente il rilevamento precoce delle deviazioni di processo, favorisce una produzione stabile e ripetibile, garantisce una qualità costante dei componenti e contribuisce a ridurre gli scarti e a evitare costosi tempi di fermo.

Nessun impatto sulla progettazione dello stampo

i sensori sono integrati nel sistema a canale caldo, non nello stampo.
Monitoraggio del processo per applicazioni multicavità

consentendo di rilevare sbilanciamenti, riempimenti incompleti e componenti sovracompressi.
Controllo del processo tramite commutazione automatica

in base al livello di pressione rilevato nella cavità.
Supporta la manutenzione predittiva

rilevando eventuali inceppamenti dello spillo o l’usura delle guarnizioni attraverso variazioni nel comportamento del movimento dello spillo.

Dimentica la complessa tecnologia dei sensori nelle cavità.

Sostituisci semplicemente il portaspillo standard del tuo sistema a canale caldo con il nuovo portaspillo intelliGate-p dotato di sensore di pressione integrato, per un monitoraggio affidabile della pressione in cavità senza sensori nello stampo.

Aggiorna e modernizza il tuo sistema a otturazione Männer esistente

Tutti i sistemi a canale caldo Männer con azionamento pneumatico PS 48.2 possono essere equipaggiati a posteriori. Il sistema può essere facilmente installato negli stampi esistenti senza richiedere alcuna modifica alla progettazione.

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.