The new generation of flow meter: versatile, powerful and economically attractive
The extended configuration options make the Flow-6 a flexible solution that can be ideally adapted to any application. Customers can choose between two variants that are customised to the respective application and the specific requirements of the user.
- Flow meter: Version with flow rate measurement only - for maximum process reliability
- Flow controller: Version with flow rate measurement and integrated Controller - for maximum efficiency
In addition, several temperature-dependent versions are available: from the particularly cost-effective version for applications up to 100 °C to the version up to 160 °C and the high-temperature version for applications up to 180 °C.
Three types with four, six or eight external circuits are also available. Extensive analyses with customers, mould makers and injection moulding machine manufacturers have shown that these combinations cover the majority of all applications. This means that every user can find the right solution - and at the same time benefit from a particularly attractive price-performance ratio:
For applications with a very high number of external circuits, several Flow-6 can also be placed in an injection moulding machine and connected together to expand the number of circuits thanks to the particularly compact design.
The Flow-6 thus offers a wide range of configuration options, allowing users to select exactly the functionality they really need - maximum flexibility connected with economic efficiency.
Proven, precise and reliable: Ultrasonic measuring principle
With the Flow-6, HB-Therm relies on a fully in-house developed ultrasonic measurement system – the same technology that has already proven itself in the Thermo-5 and Thermo-6 temperature control units. This expertise dates back to 2008, when the Thermo-5 was first equipped with ultrasonic flow measurement. Building on this experience, HB-Therm set a clear mark of its innovative strength in 2021 with the introduction of the Thermo-6 – combined with a lifetime guarantee. The company now consistently continues this tradition with the Flow-6: the guarantee explicitly applies to the measuring section, the core component of any flow meter, effectively eliminating failures and costly spare parts over the entire lifecycle.
The ultrasonic measuring principle offers outstanding precision, a fast and delay-free response to setpoint changes, and an exceptionally wide measuring range from 0.4 l/min to 40 l/min per circuit. It is capable of measuring flow in both directions, thereby also detecting incorrectly connected circuits and ensuring maximum process reliability.
A further advantage of the ultrasonic principle lies in its resilience: it operates without moving parts, is insensitive to contamination, dirt particles or pressure surges – such as those occurring during mould emptying with compressed air – and requires neither cleaning nor maintenance. The actuators used in the flow controller for each external circuit automatically calibrate themselves at every start-up.
Construction and design: Robustness meets efficiency
The Flow-6 was consistently designed for high corrosion resistance: all media-contacting components are made of stainless steel. Precisely manufactured investment-cast parts ensure optimised flow guidance. As with the Thermo-6, the flow-optimised design minimises pressure losses in the hydraulics, thereby supporting energy-efficient operation of the temperature control unit.
Optimised diameters, the avoidance of constrictions, and the use of smooth radii instead of sharp edges all contribute significantly to reducing pressure losses. This allows the required pump speed at the temperature control unit to be lowered – resulting in reduced energy consumption and lower wear.
At the same time, the Flow-6 achieves a maximum flow rate of up to 40 l/min, twice that of its predecessor, the Flow-5 (autonomous). With this extended measuring range and its compact design, the unit reliably covers a broad spectrum of applications both within and beyond its class. External connections are designed in G½, while the main connections to the temperature control unit are in G1¼.
Designed as a standalone, autonomous solution, the Flow-6 units can be positioned close to the mould thanks to their extremely compact design. The temperature control unit and Flow-6 are connected via a main line, while the connections to the individual circuits are deliberately kept short – a solution that not only significantly improves efficiency, but also minimises pressure and heat losses. As a result, energy demand is reduced, control of each circuit becomes more precise, and process reliability is increased. At the same time, the amount of hose material required is reduced, lowering both costs and environmental impact.
Compared to the previous Flow-5, the units are also lighter, making installation considerably easier. Particularly in injection moulding machines with limited installation space, the Flow-6 can be integrated manually without the need for additional lifting equipment. The flow meter variant weighs between 10 and 16 kg (depending on four, six or eight circuits), while the flow controller variant weighs between 12 and 19 kg.
Maximum process reliability
By using the Flow-6, each tool circuit is continuously monitored and documented so that the recorded data can also be used for analyses at a later date. Deviations are recognised immediately, while automatically set limit values, seamless data recording and a clearly visible LED status of the unit provide a quick overview of the operating status at all times - even from a distance. The monitoring level can be used via three preset modes (fine, middle, rough) or customised to optimally cover the requirements of different applications.
The controlled version of the Flow-6 relies on proven proportional valve technology with linear stepper motors, which has been used reliably for over 20 years to control each circuit with high precision. Thanks to the parallel tubing, all circuits are evenly supplied with tempered medium - for homogeneous temperatures, higher total flow, faster heat transfer, shorter cycle times and stable production processes.
By combining the Flow-6 flow controller with the Thermo-6 temperature control unit - especially in housing size 62, which impresses with its excellent price-performance ratio and has proven itself in numerous applications - the need for temperature control units can be significantly reduced for the same media temperature thanks to the speed-controlled pumps. Flow-6 therefore makes it possible - provided the process power is sufficient - to reduce the number of temperature control units used in a production system and at the same time combines maximum process reliability, efficiency and cost-effectiveness, even under the most demanding production conditions.
Intuitive command and efficient control system
The Flow-6 can be seamlessly integrated into higher-level systems – either at temperature control unit level via Thermo-6 or Gate-6, or directly into injection moulding machines. Thanks to its autonomous control via Gate-6, which features a display and can be flexibly positioned using a bracket or magnet, the Flow-6 operates entirely independently.
The Gate-6 offers either a graphical view or a text mode. Communication is standard via OPC UA, with additional options available through DIGITAL, CAN, or PROFIBUS-DP. Intelligent operating assistance automatically adjusts the operating mode to the optimal operating point (e.g. ΔT, flow rate), enabling even complex processes to be controlled with ease. Each circuit can be regulated individually, supporting sustainable, energy-efficient and reliable production.
The intuitive operation is based on the familiar Thermo-6 control system, meaning no new training is required. Thanks to the smart user interface, settings can be adjusted easily by tapping and swiping, supported by an integrated help system with context-sensitive information. In addition, web-based extended assistance is available in the respective local language, activated via QR code and providing direct access to HB-Therm’s “Knowledge” platform.
Compatibility and versatile integration
Active communication between the temperature control unit and the Flow-6 is particularly important in the flow controller variant, as the speed-controlled pumps must precisely adapt the water volume to the requirements of the Flow-6 in order to ensure a process-safe and energy-efficient temperature control.
The Flow-6 operates independently of the connected temperature control unit. However, a distinction must be made between the use of Thermo-6 units and third-party equipment, as their structure and functionality differ slightly.
Thanks to its optimal coordination with Thermo-6 temperature control units, the Flow-6 can be fully integrated, allowing both systems to work seamlessly together. This enables highly efficient and precise control and regulation of all circuits.
When used with other temperature control units, data transmission and circuit control are handled via the injection moulding machine, which in this case acts as the master, monitoring, managing and controlling both systems. The temperature control unit and flow meter transmit their data independently, while the injection moulding machine derives the control commands from this information and sends them back accordingly.
Digitally networked
With the Series 6, HB-Therm has taken digital networking in temperature control technology to a new level. About Gate-6 and e-cockpit, users have free access to a wide range of digital services - from data acquisition and evaluation, remote access and control to direct access to the digital twin with all relevant information.
These digital options are now also available to Flow-6 at any time. Users benefit from the same functions as with the Thermo-6 units: convenient remote control, analysis of historical data and comprehensive transparency throughout the entire process.
Safety and confidentiality are top priorities for HB-Therm: access is only granted with explicit release and meets the highest security standards for the protection of sensitive data.
Availability of Flow-6
The versions for flow rate measurement only will be available in various models from June 2026, while the models with additional control functionality will follow in January 2027. Thanks to a high degree of in-house production and automation as well as many years of expertise in development and production, the Flow-6 offers an economically attractive solution. They combine high functionality and quality with a very attractive price-performance ratio - backed by a lifetime warranty on all measuring sections.
Conclusion
Compared to serial tubing, where downstream circuits are less well cooled or heated and longer lines cause higher pressure drops, parallel tubing ensures uniform conditions throughout the mould.
The flow meter Flow-6 creates additional Safety and transparency by continuously monitoring each mould circuit and immediately detecting and documenting any deviations. This seamless traceability and early fault detection enable reliable process control - even for complex or validated applications.
The controlled version of the Flow-6 allows each circuit to be individually set to the optimum flow rate or desired temperature differences. The proven HB-Therm proportional valve technology and linear stepper motors ensure uniform temperatures, stable processes and constant heat transfer. Early deviations are automatically corrected, cycle times are shortened and operating effort is reduced.
To summarise, parallel tubing in conjunction with the Flow-6 ensures maximum transparency, process reliability and cost-effectiveness - guaranteeing efficient, long-lasting production processes.
