Powder Slush Molding 

The patented KAS Hot Air Slush System has features and benefits that no other machinery manufacturer can offer. Working on the basis of turbulent air across a surface, we increase the thermal transfer exponentially by providing a 4000+ Reynolds Number across the surface. Using turbulent hot air distribution points across the mold surface provides fast and consistent heat transfer.

KAS provides an automated tool change system that is multiple color capable and has the ability to provide sequential manufacturing. This allows mutli-platform molds such as door panel and Instrument panel molds to cycle in unison for a very efficient manufacturing system. Tool life while using this unique KAS designed system is indisputably the longest in the industry! KAS controls thermal shock in both the heating and cooling cycles which promotes longer tool life as opposed to oil line jacketed mold types. The KAS powder slush molding machine has proven tool life examples that exceed 400,000 cycles on full IP nickel shell tooling with faster cycle times than our competition.

Single or Multi-Cavity Tool Design

The KAS Slush Molding system is designed for single or multi cavity tools. Using 8 -375,000 BTU individual gas burners and 144 conditioned air deployment points. This unique temperature control system manages the tool surface temperature for outstanding processing control. The combination of servo controlled heat sources, dynamic deployment points and air velocity provides a processing window that allows for many combinations of tooling and material types to provide KAS customers a flexible powder slush molding system.

The system design has virtually no internal moving parts making the upkeep and general maintenance an easier task over conventional systems. Each air deployment point (144) has an adjustable proportioning gate and swivels allowing the maximum “per zone” heat adjustments. This feature allows both IP’s and Door geometry to be processed sequentially.

Check It Out: Pictures of KAS Hot Air Slush Skin Systems

Two Slush Mold Manufacturing Models

KAS offers two models of powder slush molding machine systems, an overhead power and free system and a center turret tool rotating system. Both have several features and benefits dependent on your molding needs. The overhead system allows greater flexibility while the turret design provides a smaller foot print should floor space be at a premium.


Understand Turbulent Flow and its Affects

Here is a video created by students at Georgia Tech, Woodruff School of Mechanical Engineering, as a project for ME 3340 Fluid Mechanics class. They demonstrate what the terms “Reynolds Number” – “Laminar Flow” and “Turbulent Flow” mean.

Effects of Turbulent Air and Reynolds Theory

When flow is turbulent, particles exhibit additional transverse motion which enhances the rate of energy and momentum exchange between them thus increasing the heat transfer and the friction coefficient.

Powder Slush Mold Systems 

KAS’s Unique “Powder Slush” molding systems continue to revolutionize the industry. Our designs have reduced cycle times through continuous improvement and process development. We offer various systems for applications from Instrument Panels to Door skins. The powder slush molded skin process continues to improve and evolve as the available chemical compositions have improved in recent years.

KAS’s latest Powder Slush Skin System, integrates two of Konal’s most successful patented technologies, Blast Cast & Smart Track overhead power free systems. This uniquely designed system provides the industry with some of the fastest cycle times possible for the powder slush molding process. This KAS slush molding system allows multi-color and fast mold changes to maximize efficiency and machine throughput.

Please contact us with any questions that you may have and one of our knowledgeable staff will be in touch right away to discuss your system requirements.

Please contact us with any questions that you may have and one of our knowledgeable staff will be in touch right away to discuss your system requirements.


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Automation Experts

Most manufacturers have been producing a component in the same way for many years and have maximized output over time. In most cases Konal looks at the process steps during and post manufacturing to understand the entire manufacturing and assembly process.

Our goal is simple… Better, faster, cheaper. Our sound engineering and ROI sales approach enables our customers to venture into areas of manufacturing that can only be described as “World Class”.

Contact KAS

1500 West Hively Avenue
Suite E
Elkhart, Indiana 46517
Email: info@konal.com
Phone:  1-574-327-2090