Industrial mold release agents and release systems
Mold release agents are chemical formulations that prevent the raw materials of the final product from adhering to the mold surface. At AITANACHEM, we formulate and supply high-performance semi-permanent industrial release agent systems. They are designed to ensure rapid demolding of parts without damaging the mold surface. Our release solutions — available in both water-based and solvent-based formulations — minimise build-up, increase release cycles per application and extend the service life of the molds. In addition, we offer personalised technical support to our customers, enabling us to tailor the release system to the specific requirements of each production process.
Table of contents
Release solutions tailored to each industrial sector and application
Every production process and industrial sector has its own specific characteristics. At AITANACHEM, we have developed release agents tailored to the specific requirements of each process. We always take into account not only the method of application, but also the characteristics of the final product, the raw materials used and the type of mold. Drawing on many years of experience and testing, we have developed specific release systems for a wide range of industrial processes and sectors.
Composites and solid surface: shower trays, gelcoat and epoxy resin
Release systems specifically developed for the manufacture of solid surface products, shower trays, polyester panels, products with gelcoat finishes and parts produced using epoxy resin, amongst others. Our semi-permanent release agents guarantee a flawless surface finish and multiple demoldings without any transfer of product to the final part.
o Find out more about mold release agents for composites and the sanitaryware industry
Polyurethane (PU): rigid foam, flexible foam, integral skin and RIM
Release technology for rigid foam, flexible foam, integral skin, RIM, RRIM, TPU and injected polyurethane systems. Our release agents designed specifically for these processes guarantee excellent part definition and aesthetic finishes free from imperfections or marks.
o Discover our range of semi-permanent release agents for polyurethane foams and molded parts
Rubber and tyres: high-temperature vulcanisation
Release agent systems based on high-performance polymers that impart high non-stick properties and lubricity to the surface to which they are applied. Specially designed to withstand the demanding vulcanisation conditions of the rubber and tire manufacturing industries. They are characterised by high thermal resistance and zero transfer of product to the final part. This last point makes them particularly attractive, as it eliminates the need to wash the parts after demolding — a step typically required with the sacrificial release agents and waxes traditionally used in this industry.
o Discover our release agents for rubber and tire manufacturing
Rotational molding: ovens above 200 °C
In an industry where ovens reach temperatures of over 200 degrees, it is essential to use solvent-free products that ensure a safe working environment. At AITANACHEM, we have developed a water-based semi-permanent release agent, specifically designed for this sector, which guarantees a safe working environment whilst remaining easy to apply and use. Our external release agents for rotational moulding facilitate the removal of parts with complex geometries, drastically reducing the build-up in the mould.
o Discover our release agents for rotational molding.
Mold preparation, cleaning and maintenance
Efficient demolding requires a mold surface that is completely clean and free from contamination. The cleaner the mold, the greater the cost-effectiveness of the release agent and the higher the quality of the final part. A clean mold ensures that the molded part faithfully replicates the shape of the mold. At AITANACHEM, we understand that a release system is not based solely on a good release agent: it must also include the products required for the correct preparation and comprehensive maintenance of molds. That is why, to complete our range, we offer our customers:
- Industrial mold cleaners: specifically formulated according to the type and degree of soiling on the mold. They enable the rapid removal of residues accumulated during production, whilst keeping the mold’s surface properties intact. Our portfolio includes a wide range of solvent-free cleaners.
- Mold sealants: following a thorough cleaning of the mold (two or three times a year, depending on its use), it is advisable to apply a mold sealant. Sealants close micropores and surface imperfections in the mold — in many cases imperceptible to the naked eye. They significantly improve the effectiveness of release agents and protect the mold surface, considerably extending its service life.
Discover our products specially designed for mold treatment and maintenance.
Comparison: water-based or solvent-based release agents?
| Characteristic | Water-based release agents | Solvent-based release agents |
|---|---|---|
| Environmental impact | None or very low VOCs. | VOC emissions. Requires adequate ventilation. |
| Workplace Safety | Non-flammable, safer working environment. | Flammable, toxic and potentially explosive. Carries health hazard statements. |
| Evaporation Time | Moderate. | Immediate at room temperature. |
| Main Application | Plants with stringent environmental requirements. Requires greater technical knowledge. | Ultra-short cycle times. Simpler to apply. |
| Transport and storage | Neutral product. No special storage requirements. | Dangerous goods – ADR. Subject to legislation on the storage of flammable products. |
Personalised technical support and tailored release solutions
At AITANACHEM, we support our customers throughout the entire process of implementing release systems into their production lines. Our high level of technical expertise and the experience we have gained over many years enable us to offer technical support that guarantees a rapid response and the adaptation of release agents to the specific requirements of each production process. This personalised support and our ability to propose bespoke release solutions are, without a doubt, our greatest competitive advantage over large release agent manufacturers.
💡 Are you experiencing problems with parts sticking or with build-up in your molds?
Please do not hesitate to contact us. Our technical team will analyse your process and send you the products best suited to your needs so that you can test them and verify their quality and efficiency. Throughout this phase, you will have our technical support to ensure the correct application of the proposed release system. Based on the results of your tests, we will assess the possibility of tailoring the release agents to the specific characteristics of your project.
Frequently Asked Questions (FAQs) about release agents
What is a semi-permanent release agent?
A release agent acts as a physical barrier between the mold surface and the molded material. Its function is to prevent the molded material from sticking to the mold (anti-adhesion) and to facilitate the removal of the finished part (lubricity). Semi-permanent release agents bond firmly to the mold walls. Unlike sacrificial release agents and waxes, which require continuous application, a single application of this type of release agent allows for multiple consecutive demolding cycles without reapplying the product. This distinctive feature enables an immediate increase in productivity, a reduction in build-up on the mold and virtually no transfer of product to the final part.
How can build-up in the mould be reduced?
BBuild-up in the mold is usually caused by the use of wax- or silicone-based release agents, by an excess of product, or by the release agent not curing properly. The consequences are a shorter mold service life and higher costs arising from regular cleaning. By using semi-permanent release agents and preparing the molds correctly (cleaning and sealing), this problem is eliminated. As semi-permanent release agents are far more efficient than traditional ones, they require a smaller amount of product to release the part. This means less release agent is applied to the mold surface and, consequently, less residue builds up.
Do release agents affect the subsequent painting or bonding of the part?
Our semi-permanent release agents have been specifically formulated to prevent the transfer of silicones or oils to the demolded part. In this way, we ensure that the surface of the final product is ready for subsequent processes such as sanding, painting or structural bonding. This is a considerable competitive advantage over traditional release agents, as it eliminates the need to wash or clean the parts after demolding.
How can you tell whether a semi-permanent release agent is of good quality?
The simplest way is to check the expiry date provided by the manufacturer. If the semi-permanent release agent has a shelf life of at least one year, this is evidence of chemical stability, which often confirms the product’s good quality.
What is the difference between internal and external release agents?
Internal release agents are additives incorporated into the raw materials which, during the production process, migrate to the outer surface of the molded product. They thus act as a physical barrier between the mold surface and the molded material, preventing it from sticking to the mold. External release agents work the other way round: they are applied directly to the mold surface before the raw materials are introduced. At AITANACHEM, we recommend the use of semi-permanent external release agents, as they ensure better release and less build-up of residue in the mold.
Optimise your demolding process with AITANACHEM
Choosing the right release agent for your process does not only prevent parts from sticking to the mold: it is a technical decision that determines the profitability of your plant, the quality of the final product and the service life of your molds. At AITANACHEM, we combine the development of semi-permanent release systems with ongoing technical support to solve our customers’ demolding problems in the production of solid surface, composites, polyurethane, rubber and rotational molding.
Do you need a release agent tailored to your process?
Whether you are looking to reduce your defect rate, eliminate residue build-up in your molds or switch to more sustainable technologies such as solvent-free release agents and cleaners, our team is on hand to recommend the best release solution for your process. Please do not hesitate to contact us. We will analyse the characteristics of your process and send you the most suitable release system so that you can verify at your own premises that it meets your requirements.
Find out more on our blog specialising in industrial release systems
To help you keep your processes at the cutting edge, we regularly publish practical guides, comparisons and application tips on industrial release systems, written by our specialists. We recommend you take a look at our posts:
o Step-by-step guide: How to apply water-based release agents correctly (Includes explanatory video)
o Eco-friendly solutions: Solvent-free mould cleaners
📚 Explore all our technical articles, case studies and the latest news on the formulation of release systems in our blog category: