Components of release agent mixer includes components:

• Mixing container
• Stirring mechanism
• Control system
• Auxiliary system

The mold release agent mixer is mainly used in the preparation of mold release agents in industrial production.

Die casting is an efficient, precision manufacturing process for producing complex metal parts with tight tolerances, widely used in automotive, aerospace and consumer electronics.

A release agent mixer is dedicated equipment. It dilutes concentrated release agent with water or other carriers in precise proportions and delivers uniform, stable mixing.

This directly determines casting quality, mold durability and production efficiency.

Improper mixing causes inadequate lubrication, casting defects such as sticking, surface flaws and porosity, accelerates mold wear and raises operating costs.

This article introduces the mixer’s core structure, working principle, operation rules, selection standards and maintenance measures, as well as its role in die casting process optimization.

Fully automatic die casting release agent mixers serve the foundry industry and suit aluminum and cast iron die casting applications.

Release agents are vital in casting, automotive integrated die casting, plastic and rubber industries, driving rising market demand for such mixing equipment.

Components of release agent mixer

• Mixing container
• Stirring mechanism
• Control system
• Auxiliary system

Mixing container

Material: Stainless steel is usually adopted, which has corrosion resistance, weldability and strength.

It is especially suitable for mold release agents containing corrosive components (such as silicone oil, organic acids, etc.).

Volume: Adjusted according to the production scale, the volume of laboratory-grade equipment can be as low as 1.5L, while that of industrial-grade equipment can reach over 200L.

Sealing design: The airtight structure prevents evaporation or leakage.

Some equipment adopts clamp-type flange sealing and butterfly valve discharge ports to reduce residue.

Stirring mechanism

Low-viscosity liquids: paddle type, turbine type, and propeller type agitators, operated under turbulent conditions, with the ratio of impeller diameter to container diameter being 0.3-0.6.

High-viscosity liquids: Anchor, helical ribbon or screw agitators are used to achieve uniform mixing through laminar or transitional flow.

Drive system: The motor power range is from 1.5kW (for small equipment) to 18.5kW.

For industrial equipment, and the speed is adjustable to meet different mixing requirements.

Control system

Automation function: The fully automatic model adopts PLC control to set parameters such as stirring time and speed and monitor the entire process.

Safety protection: Overload protection, temperature sensor (for high-temperature release agents) and emergency stop function.

Auxiliary system

Heating/cooling device: Some release agents need to be mixed at specific temperatures such as high-temperature resistant silicone oil release agents.

And the equipment may be equipped with jackets or electric heating elements.

Atomization module: Then,the aerosol type mold release agent mixer integrates a high-pressure nozzle to atomize and spray the mixed liquid onto the mold surface.

The definition and core functions of the mold release agent mixer

• High-efficiency mixing
• Automation control
• Adapt to diverse demands

The mold release agent mixer is an industrial equipment specifically designed for preparing mold release agents.

It uniformly mixes the various components of the mold release agent.

Such as oil, water, emulsifiers, additives, etc, through physical or mechanical means to ensure the stable performance of the mold release agent.

High-efficiency mixing

Solve the stratification problem of solid suspensions such as wax, silicone oil.

And liquids in mold release agents, ensuring the uniformity of components.

Automation control

The fully automatic model equips itself with a PLC system to precisely adjust the stirring time and speed, reducing manual intervention.

The equipment’s inherent automation features reflect the automation of the release agent mixer in the Haichen die-casting machine.

Such as fully automatic mixing and the overall automation trend of the die-casting system such as central control systems, robotic control, etc.

However, despite the limited independent automation control details for the release agent mixer itself, the automation technologies of the overall die-casting system.

Such as automated control, sensors, PLCs,provide support for the automation application of the release agent.

Adapt to diverse demands

It can handle water-based, oil-based and mixed mold release agents, meeting the requirements of different industries for the viscosity, temperature resistance and other characteristics of mold release agents.

Selection Criteria for Release Agent Mixer in Die Casting

Release agent usually water-miscible, sprayed onto the wall of the die casting mold during pressure die casting.

Selecting the right release agent mixer is critical to matching the specific needs of the die casting process. Key selection criteria include:

• Mixing Capacity
• Proportioning Precision
• Material Compatibility
• Automation Level
• Compatibility with Die Casting Machine
• Maintenance and Durability

Mixing Capacity

The mixer’s capacity should align with the die casting machine’s output—smaller machines (250-3000 tons) may require a single-unit mixer.

While large-scale production may need a centralized mixer that supplies multiple die casting machines via pipelines.

Proportioning Precision

The mixer should offer precise control over the mixing ratio (with an accuracy of ±1% to ±5%) to accommodate different release agent types and casting requirements.

This is particularly important for water-based release agents, which require strict ratio control to ensure performance.

Material Compatibility

Design the mixer’s components with corrosion-resistant materials to resist the chemical properties of release agents, prevent contamination and avoid equipment damage.

Automation Level

We recommend a fully automated mixer with PLC control, touch panel interface, and automatic level and pressure monitoring for high-volume production to cut labor costs and maintain stable processing consistency.

Manual or semi-automated mixers may be suitable for small-scale or low-volume production.

Compatibility with Die Casting Machine

The mixer shall synchronize with the die casting machine’s spray system to deliver release agent at the optimal time throughout the casting cycle.

It should also be compatible with the machine’s spray nozzles and pressure requirements.

Maintenance and Durability

The mixer should be designed for easy maintenance, with accessible components that can be quickly cleaned or replaced.

A robust design is essential to withstand the harsh industrial environment of die casting plants.

Mold release agent mixer and die-casting process

Under the die-casting processes of different types of metals, the mixture of release agents will also vary:

• Aluminum alloy die casting
• Magnesium alloy die-casting
• Zinc alloy die casting

Aluminum alloy die casting

The release agent mixer is widely used in aluminum alloy die casting.

It is used to spray the surface of the mold to form an isolation film, preventing the metal liquid from directly eroding the mold, and improving the forming quality of the casting and production efficiency.

Magnesium alloy die-casting

During the magnesium alloy die-casting process, the release agent mixer reduces mold wear by spraying release agent, ensuring the integrity and surface quality of the castings.

Zinc alloy die casting

The release agent mixer is used in zinc alloy die casting to help the molten metal enter the cavity.

And form a uniform isolation film, thereby improving the demolding performance and quality of the casting.

The collaborative process of mold release agent mixer in die-casting technology

• Mold release agent preparation stage
• Pre-treatment stage of die-casting
• Die-casting and post-processing stage

Mold release agent preparation stage

The mixer blends the original mold release agent solution with water in a specific ratio (e.g., 1:140) and forms a stable emulsion via agitators or emulsifying pumps.

Haichen’s mold release agent mixer comes with a recovery device that separates oil and water from unused mold release agent, filters and reclaims them, thus reducing production costs.

Pre-treatment stage of die-casting

The mixed release agent is conveyed through pipelines to the spraying device of the die-casting machine.

And evenly covers the surface of the mold in the form of atomization, forming a high-temperature resistant (400-600℃) isolation film.

The spraying volume needs to be precisely controlled (usually 0.1-0.3L/m²).

Excessive spraying will cause gas holes on the surface of the casting, while insufficient spraying is prone to sticking to the mold.

Die-casting and post-processing stage

The release agent reduces the thermal shock of the mold during the metal liquid filling process, lubricates the flow channels at the same time, and improves the filling integrity.

After the casting is demolded, the residual mold release agent is collected through the collection system of the die-casting machine chassis and enters the oil separator for treatment to prevent environmental pollution.